Flow Activated Sensor Assembly for Downhole Firing Head Activation
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Solution Overview
Problem
Existing methods for activating downhole firing heads in oil wells, such as the ball-drop technique, are inefficient and unreliable, especially in environments where liquid flow is not feasible, leading to significant time delays and reduced accuracy in triggering the firing head.
Innovation Solution
A flow activated sensor assembly is introduced, which includes an oilfield tubular with a channel for fluid-flow and a flow translation device that detects fluid flow signatures, allowing for timely and accurate triggering of the firing head, even in the presence of gas or intermittent flows, using a detector coupled to the device for communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If ball-drop technique is used to activate firing head, then activation can be achieved in coiled tubing operations, but significant time delay occurs (averaging 30 minutes or more)
Solution Approach 1:
The system pre-establishes a flow signature pattern before the actual firing operation. By pumping fluid through the coiled tubing ahead of time and establishing the signature pattern, the system eliminates the need for time-consuming ball-drop operations later, enabling immediate response when firing is required.
Solution Approach 2:
The patent replaces the mechanical ball-drop system with a flow-based actuation system. Instead of using physical balls to trigger the firing head, the system uses fluid flow signatures detected by a flow detector to automatically activate the firing head, eliminating mechanical delays and enabling faster response.
2Measurement precision
If ball-drop technique is used, then firing head can be activated in coiled tubing, but precision and accuracy of triggering is reduced
Solution Approach 1:
The system incorporates a flow detector that continuously monitors fluid flow through the coiled tubing and provides feedback to a control system. This feedback mechanism allows the system to detect when the flow signature matches the pre-established pattern, enabling precise and reliable triggering of the firing head at the correct moment.
Solution Approach 2:
By replacing the mechanical ball-drop system with an electronic flow detection and control system, the patent achieves higher precision and reliability in triggering the firing head. The electronic detection and control mechanisms provide more accurate timing and positioning compared to manual ball-drop operations.
3Loss of time
If liquid flow is used for flow signature detection, then timely activation can be achieved, but well production may be disrupted
Solution Approach 1:
The system allows for parameter changes in the fluid type used for flow signature detection. Instead of being limited to liquid flows, the system can detect flow signatures in gas phases as well, enabling timely activation while using inert gases that do not disrupt well production operations.
Solution Approach 2:
The patent employs inert gases (such as nitrogen) for flow signature detection instead of liquids. This allows the system to achieve timely activation through flow-based detection while using inert atmospheres that do not interfere with or disrupt ongoing well production operations, maintaining compatibility with existing well conditions.
4Reliability
If conventional flow detectors are used with gas flow, then activation can be attempted, but detection reliability is poor
Solution Approach 1:
The system employs parameter changes in the detection approach by adapting the flow signature detection method to work effectively with gas phases. By modifying the detection parameters and using flow detectors capable of detecting gas flow patterns, the system achieves reliable detection and activation even in gas-filled coiled tubing environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The flow activated sensor assembly enables reliable and precise activation of downhole tools, independent of fluid consistency, enhancing the speed and accuracy of operations like perforating, without disrupting well production by using inert gases, and maintaining operational efficiency across various well conditions.
Implementation Method 1
a flow translation device disposed within the channel for responsive movement upon exposure to the fluid flow
Data Source
AI summary
A sensor assembly for detection of fluid flow signaling over a tubular conveyance. The assembly may be employed for activation of a variety of different downhole actuators such as firing heads for perforating guns or hydrostatic set modules for packer deployment. The assembly is configured with a flow translation device which is disposed in a manner exposed to fluid flow directed through an oilfield tubular coupled to the assembly. Thus, a detector coupled to the translation device may obtain mechanical data from the device which is reliably indicative of the flow, irrespective of the physical nature of the flow itself. As such, enhanced reliability for subsequent actuator firing based on the flow signaling may be achieved.