Instrumented Coupling Gauge Mandrel for Downhole Sensor Integration
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Solution Overview
Problem
Conventional instrumented couplings for downhole wells are costly and prone to manufacturing errors due to high precision requirements, with gun drilling processes being expensive and difficult to execute, leading to increased labor and material costs, and sensor components being vulnerable to damage from movement within small openings.
Innovation Solution
An instrumented coupling design where the carrier serves as both a coupling and a housing for sensors and electronics, with offset bore and larger cavities machined into the carrier wall, allowing for easier installation and securing of sensors using clamps, and eliminating the need for separate sensor housings and costly gun drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gun drilling is used to create cavities in the carrier wall, then sensors can be installed within the carrier wall, but the manufacturing process becomes very costly and requires very high precision
Solution Approach 1:
The cavity formation process is segmented into multiple steps: initial drilling of a smaller diameter hole, followed by expanding the cavity using an expanding tool or mandrel. This segmentation allows the use of standard drilling equipment rather than expensive gun drilling, while still achieving the required cavity size for sensor installation.
Solution Approach 2:
A smaller pilot hole is drilled first as a preliminary action, which then serves as the starting point for expanding the cavity. This preliminary hole provides guidance and structural support during the expansion process, ensuring the final cavity maintains proper dimensions and position without requiring high-precision gun drilling.
2Reliability
If gun drilling is used to create cavities, then sensors can be positioned within the carrier wall, but installation and soldering become very difficult requiring more time and labor
Solution Approach 1:
The cavity is designed with a larger opening that provides segmented access points for sensor installation. The expanded cavity allows sensors to be inserted and positioned more easily compared to narrow gun-drilled holes, reducing installation time while maintaining secure positioning within the carrier wall.
Solution Approach 2:
An expanding tool or mandrel is used as an intermediary during cavity formation. This tool creates the expanded cavity space and can remain in place to provide structural support and access during sensor installation, making the installation process less difficult and time-consuming.
3Reliability
If sensors are installed in small gun drilled holes, then they can be enclosed within the carrier wall, but the components are subject to damage from movement within the holes
Solution Approach 1:
The cavity is expanded to provide additional space within the carrier wall, creating a larger chamber that can accommodate sensors with minimal movement. This segmented space allows sensors to be securely positioned without the constrained movement that occurs in narrow gun-drilled holes, reducing the risk of damage.
Solution Approach 2:
The expanded cavity design inherently provides cushioning space around the sensors before any damage can occur. This additional volume acts as a buffer that prevents sensors from moving excessively or coming into contact with the carrier wall, thereby protecting them from damage during installation and operation.
4Ease of operation
If a conventional mandrel with external sensor packages is used, then sensors can be installed on the exterior, but substantial material is required forming a costly mandrel
Solution Approach 1:
The sensor packages are merged with the carrier wall by creating cavities within the wall itself. This combines the structural function of the carrier with the housing function for sensors, eliminating the need for separate external sensor packages and their associated tubular housings, thereby reducing material consumption.
Solution Approach 2:
The sensors and their minimal housing are nested within the carrier wall cavities. This nesting arrangement allows the sensors to be contained within the existing carrier structure rather than requiring additional external materials, significantly reducing the total quantity of material needed compared to conventional external mounting.
5Object-affected harmful factors
If separate tubular housings are provided for each sensor package, then sensors are protected, but the overall amount of material and cost increases
Solution Approach 1:
The protective housing function is merged with the carrier wall itself. The carrier wall cavities serve as the protective enclosure for sensors, eliminating the need for separate tubular housings. This integration maintains sensor protection while significantly reducing the total amount of housing material required.
Solution Approach 2:
The carrier wall is given multiple functions: it provides structural support for the carrier, contains cavities for sensor housing, and protects the sensors from environmental damage. This multi-functionality eliminates the need for separate protective housings, reducing material consumption while maintaining protection.
6Adaptability or versatility
If ports are drilled from exterior pockets to the bore and manifolds are mounted, then sensors can measure conditions within the bore, but the manufacturing process becomes more complex
Solution Approach 1:
The manifold component is extracted from the design and its function is integrated directly into the carrier structure. The carrier wall cavities are configured to provide direct access to the bore, eliminating the need for separate ports and manifolds, thereby reducing manufacturing complexity while maintaining measurement capability.
Solution Approach 2:
The port and manifold functions are merged into the carrier wall cavity design. The cavity itself provides the pathway from the exterior to the bore, and the cavity structure serves as the mounting interface, eliminating the need for separate port drilling and manifold installation steps.
Data Source
AI summary
A compact instrumented downhole coupling that includes a carrier and a set of sensors and electronics that are installed within the carrier. The carrier is a tubular structure having couplings at each end and a bore therethrough, where cavities are formed in the carrier wall. The cavities are open to a side facing away from the carrier's bore, where sensors placed in the cavities are accessible through the side opening. Electrical connections to the sensors are made via the side opening, and a clamp can be installed in the cavities via the side opening, the clamp holding the sensors securely in position within the cavities. After installation of the sensors in the cavities, plates are welded over the side opening to form an enclosure for the sensors in the carrier wall.