Gravity-Actuated Sensor for Downhole Toolface Measurement

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Solution Overview

Problem

Current drilling technologies face challenges in accurately determining the gravity toolface, inclination, orientation, and temperature downhole, especially in deviated and horizontal wellbores, due to limitations in existing sensor technologies that are affected by vibration and require stationary measurements.

Innovation Solution

A sensor apparatus with a plurality of spaced conductive contact elements and a gravity-affected sensing member that creates an electrical short between contact elements, coupled with a circuit to generate signals for processing these parameters, allowing for accurate determination of toolface, inclination, orientation, and temperature measurements even when the drilling assembly is rotating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If magnetometers are used to provide measurements of the toolface, then measurements are unaffected by BHA vibration, but measurements can only be taken when the BHA is rotating and require reference to gravity toolface measurements taken when stationary

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoidmeasurement system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/gravity-based sensing system with a magnetic field-based magnetometer system. The magnetometer measures the toolface by detecting the magnetic field orientation rather than relying on gravity-dependent mechanical sensors, thereby eliminating the need for stationary reference measurements and reducing system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnetometers as an intermediary measurement device that indirectly determines toolface orientation through magnetic field detection. This intermediary approach allows continuous measurement during rotation without requiring direct gravity-based reference points, resolving the contradiction between reliability and complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If gravity-affected sensors are used to determine toolface, then measurements can be taken when the BHA is stationary, but measurements are affected by BHA vibration

Engineering Contradiction:

Improvemeasurement operation easeVSAvoidmeasurement reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces gravity-affected mechanical sensors with magnetometers that measure toolface through magnetic field orientation. This substitution eliminates vibration sensitivity while maintaining the ability to take measurements during both stationary and rotating conditions, thereby improving reliability without sacrificing operational ease.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of information

If existing sensor technologies are used in deviated and horizontal wellbores, then drilling parameters can be monitored, but accurate determination of gravity toolface, inclination, orientation, and temperature is challenging

Engineering Contradiction:

Improveparameter measurement accuracyVSAvoidsensor system complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The patent implements a multi-functional sensor system where magnetometers serve multiple purposes: determining toolface orientation, inclination, and orientation in deviated and horizontal wellbores. This universal approach provides accurate determination of multiple parameters simultaneously, reducing information loss without proportionally increasing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes the measurement parameters from gravity-based to magnetic field-based measurements. This parameter change enables accurate determination of toolface, inclination, orientation, and temperature in complex wellbore configurations by utilizing magnetic field orientation rather than gravity-dependent measurements.

Inventive Principle:

Principle #35Parameter changes

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 precise and reliable measurements of toolface, inclination, orientation, and temperature downhole, independent of vibration, enhancing the steering and monitoring of drilling operations in complex wellbore configurations.

Implementation Method 1

a sensing member that moves by gravity and contacts at least two contact elements in the plurality of contact elements to create an electrical short between such at least two contact elements

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS9163498B2Apparatus and methods for determining parameters downhole using gravity-affected sensor

Publication Date: 2015.10.20 BAKER HUGHES CO

AI summary

In one aspect, an apparatus for use in a wellbore is provided that in one embodiment includes a sensor having a plurality of spaced conductive contact elements, a sensing member that moves by gravity and contacts at least two contact elements in the plurality of contact elements to create an electrical short between such at least two contact elements and a circuit coupled to the contact elements configured to generate electrical signals in response to the electrical short between the contact elements.