Closed-Loop Magnetostrictive Sensor for Downhole Parameter Measurement

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Solution Overview

Problem

Existing downhole sensor systems face challenges in accurately measuring downhole parameters such as pressure, temperature, and vibration while withstanding harsh downhole environments, including high pressures and temperatures, due to limitations in durability and sensitivity.

Innovation Solution

A closed-loop magnetostrictive sensor system comprising a magnetic field generating member, a waveguide, and a sensor housed in a robust chamber designed to withstand downhole conditions, where the magnetic field generating member and waveguide are responsive to sensed parameters, allowing for precise measurement of downhole parameters like pressure and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sensors are used in downhole environments, then the device complexity is reduced, but the reliability and measurement precision deteriorate due to harsh conditions

Engineering Contradiction:

Improvesensor reliabilityVSAvoidsensor system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor system is divided into distinct functional segments: a magnetic field generating member (permanent magnet), a waveguide component with magnetostrictive properties, and a separate sensor element. This segmentation allows each component to be optimized for its specific function while being housed in a robust downhole-compatible enclosure, thereby improving reliability without excessive complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The waveguide acts as an intermediary element that couples the magnetic field generating member to the sensor. It transmits mechanical deformations caused by downhole parameters (pressure, temperature, vibration) to the sensor through magnetostrictive effects, enabling indirect measurement that protects the sensor from direct exposure to harsh conditions while maintaining measurement precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If robust housing is used to withstand downhole environment, then the reliability improves, but the measurement precision may worsen due to signal attenuation

Engineering Contradiction:

Improveenvironmental withstand capabilityVSAvoidparameter measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The waveguide serves as a mediator that efficiently transmits mechanical signals from the downhole environment through the robust housing to the sensor elements. Its magnetostrictive properties enable it to convert external physical parameters into magnetic field changes that can be detected by the sensor, maintaining measurement precision despite the protective housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces direct mechanical coupling between the sensor and downhole environment with a magnetic field-based measurement mechanism. The magnetic field generating member creates a magnetic field that interacts with the waveguide, and changes in this interaction due to external parameters are detected electrically, eliminating the need for direct mechanical signal transmission through the housing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If magnetostrictive sensing mechanism is implemented, then the measurement precision improves, but the device complexity increases

Engineering Contradiction:

Improvedownhole parameter detection accuracyVSAvoidsensor structure complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The invention merges multiple functions into a compact integrated structure: the magnetic field generating member is positioned in direct association with the waveguide, which itself is coupled to the sensor elements. This merging of magnetic generation, magnetostrictive transduction, and sensing functions into a single integrated assembly achieves high measurement precision while controlling overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 system effectively measures and monitors downhole parameters with high accuracy and reliability, even in extreme conditions, enhancing the operational efficiency of resource exploration and recovery systems.

Implementation Method 1

Methodology Applied

Scientific EffectMagnetostriction: Magnetostriction

Data Source

PatentUS10007016B2Downhole closed-loop magnetostrictive sensing element for downhole applications

Publication Date: 2018.06.26 BAKER HUGHES CO

AI summary

A downhole closed-loop magnetostrictive sensor includes a magnetic field generating member and a waveguide operatively connected to the magnetic field generating member. At least one of the waveguide and the magnetic field generating member is responsive to a parameter being sensed. A sensor is operatively connected to the waveguide, and a housing includes a chamber enclosing the magnetic field generating member, the waveguide and the sensor. The housing is configured and disposed to withstand a downhole environment.