Downhole Flow Control Device Noise Sensing for Uphole Telemetry
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Solution Overview
Problem
Current downhole tools with flow control devices are unable to send up-link data to the surface, limiting the ability to monitor and control the position and operation of these devices, which is crucial for optimizing fluid production and injection processes.
Innovation Solution
Incorporating sensors that detect changes in noise generated by flow control devices to wirelessly transmit operational data to the surface, using fiber optic cables with distributed acoustic sensing or hydrophones, and employing mesh networks or central collection modules for real-time bi-directional communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flow control devices are installed to balance fluid production along the wellbore interval, then production control and conformance are improved, but the ability to monitor and control device position and operation is lost due to lack of up-link communication
Solution Approach 1:
The patent implements a feedback mechanism by installing sensors (acoustic, vibration, position sensors) on or near the flow control devices that detect operational parameters and transmit this data uphole via the cable system. This allows real-time monitoring of device position, flow rates, and operational status, enabling closed-loop control where surface systems can adjust device settings based on actual downhole conditions, thus resolving the information loss problem while maintaining production optimization capabilities
Solution Approach 2:
The patent replaces traditional mechanical telemetry methods with acoustic and vibration-based sensing systems. Instead of relying on mechanical linkages or electrical contacts for data transmission, the system uses acoustic sensors and vibration sensors that detect device operation through sound waves and mechanical vibrations transmitted through the wellbore fluid and cable, enabling wireless-like monitoring without requiring complex wired mechanical systems
2Reliability
If sensors are added to monitor flow control devices, then real-time monitoring capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a multi-functional cable system that serves multiple purposes: it provides power to downhole devices, acts as a communication conduit for telemetry data, and functions as a sensor array through distributed acoustic sensing (DAS) and distributed temperature sensing (DTS) capabilities along the cable length. This universal system eliminates the need for separate dedicated sensor systems, reducing overall complexity while maintaining comprehensive monitoring capabilities
Solution Approach 2:
The patent implements self-service monitoring by utilizing the existing cable infrastructure already present in the wellbore for other purposes (power and telemetry). The cable itself becomes the sensing element through integrated acoustic and temperature sensors, eliminating the need for separate power sources and communication systems for the sensors. The system uses the wellbore fluid and cable structure as the transmission medium for acoustic signals, allowing sensors to monitor device operation without requiring additional complex infrastructure
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
Enables real-time monitoring and control of downhole flow control devices, allowing for optimized fluid management and increased production of desired fluids by adjusting the operation of flow control devices based on fluid composition and health.
Implementation Method 1
the sensor configured to sense for and send uphole operational data originating from the flow control device, the operational data in the form of a change in noise emanating from the flow control device
Data Source
AI summary
Provided is a downhole tool, a well system, and a method. The downhole tool, in one aspect, includes a flow control device coupleable with a tubing string, the flow control device configured to allow fluid to pass between an outside diameter (OD) of the tubing string and an inside diameter (ID) of the tubing string. The downhole tool, in accordance with another aspect, includes a sensor positioned proximate the flow control device, the sensor configured to sense for and send uphole operational data originating from the flow control device, the operational data in a form of a change in noise emanating from the flow control device.