Flow Electrification Downhole Sensor for Autonomous Fluid Control
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Solution Overview
Problem
There is a need for improved autonomy and accuracy in downhole flow control devices, particularly in remote locations, while minimizing energy usage and effectively managing fluid composition in oil and gas production, where existing devices struggle with efficient energy harvesting and accurate fluid monitoring.
Innovation Solution
The use of a generating material with a fluid contact surface that generates an electric charge in response to flowing fluids, coupled with a signal source to provide monitoring signals or power, and a flow control mechanism activated by these signals to manage fluid flow, optimizing contact surface area and permeability for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If autonomous inflow control devices are used to improve autonomy and reduce water production, then operational independence is improved, but measurement precision and control accuracy deteriorate due to lack of continuous monitoring
Solution Approach 1:
The device uses flow electrification sensors that automatically generate electrical signals from the flowing fluid itself, enabling autonomous detection of fluid composition without external power sources or continuous human intervention. The sensor converts the kinetic energy of flowing fluids into measurable electrical signals that trigger autonomous valve actuation.
Solution Approach 2:
The system incorporates continuous fluid monitoring with immediate feedback control - when the sensor detects changes in fluid composition (such as water cut increases), it automatically generates control signals that trigger the valve to adjust flow, creating a closed-loop autonomous control system that maintains measurement precision through real-time monitoring.
2Measurement precision
If downhole sensors and equipment are installed to monitor fluids and provide control signals, then measurement and control capabilities are improved, but energy consumption increases
Solution Approach 1:
The flow electrification sensor is a passive device that generates its own electrical signals from the flowing fluid's kinetic energy through charge separation at the sensor surface. This eliminates the need for external power sources, batteries, or complex energy harvesting systems, enabling continuous monitoring without increasing downhole energy consumption.
Solution Approach 2:
The invention replaces active electronic sensing systems that require power with a passive flow electrification effect that converts mechanical flow energy directly into electrical signals. This substitution eliminates the need for powered sensors, transmitters, and associated energy management equipment in the downhole environment.
3Power
If generating material with large contact surface area is used to harvest energy, then energy generation is improved, but pressure drop increases
Solution Approach 1:
The generating material is positioned at specific locations where fluid flow characteristics maximize charge separation while minimizing flow resistance. The sensor surface is configured to interact with the flow in a localized manner that generates sufficient electrical signals without creating significant pressure drop across the device.
Solution Approach 2:
The generating material employs a porous structure that provides large surface area for fluid interaction and charge generation while maintaining high permeability. The porous architecture allows fluid to pass through with minimal resistance while maximizing contact between the flowing fluid and the charge-generating surface.
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
This solution enables improved autonomous control and accurate monitoring of fluid properties, such as water cut, while minimizing energy consumption and pressure drop, allowing for efficient energy harvesting and fluid management in downhole environments.
Implementation Method 1
WO 2015/094147 A1 (Fripp) teaches that flow electrification sensors and methods relating thereto may be useful in characterizing fluids
Implementation Method 2
a flow electrification sensor comprising a static charge accumulator and an insulator arranged such that the static charge accumulator interacts with a fluid in the flow path
Implementation Method 3
a generator that generates electrical energy in response to a flow of an electrically conductive fluid
Implementation Method 4
a magnetostrictive material disposed proximate to the inner sleeve to be strained due to a rotation of the inner sleeve in response to a fluid flow in the flow way
Data Source
Figure 1
Figure 2a
Figure 2b~2c
AI summary
There are described downhole devices, methods and other apparatus, which may be used to generate energy, monitor fluids and/or provide control signals or otherwise trigger for actuation. The devices, methods, etc. may provide improved autonomy and/or accuracy, while at the same time minimise any effect on the operation of a well. Such devices and methods may be particularly useful downhole and in remote locations. An example of a device comprises a generating material having a fluid contact surface, that contact surface being configured to be in contact with a fluid downhole. The generating material may be configured to generate an electric charge at the material in response a fluid at the contact surface. In some examples, the device further comprises a signal source configured to provide a signal in response to a generated electric charge at the generating material.