Immersion Microsystem Packaging for Wellbore Pressure Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing microsystems face challenges in withstanding harsh wellbore environments, such as high pressures and temperatures, while effectively sensing and recording environmental conditions like pressure, temperature, and magnetic fields, and require cost-effective and reliable deployment methods.
Innovation Solution
An autonomous microsystem with a deformable polymeric shell and low-density filler particles, combined with a wireless power transfer circuit and flexible pouch, allows for density control and efficient data logging in extreme conditions, using a rechargeable battery and electronic relays for power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the microsystem uses a rigid encapsulating package to withstand harsh wellbore environments (high pressure up to 50 MPa and temperature up to 150 °C), then the structural strength and reliability are improved, but the ability to sense and transfer pressure data to the sensing elements deteriorates
Solution Approach 1:
The encapsulating package is divided into two distinct functional layers: an outer rigid shell providing structural strength and environmental protection, and an inner deformable membrane enabling pressure sensing. This segmentation allows each layer to specialize in its primary function without compromising the other.
Solution Approach 2:
The deformable membrane acts as an intermediary element between the harsh external environment and the sensitive internal sensing components. It transmits pressure changes from the external fluid to the sensing elements while isolating them from direct exposure to corrosive chemicals and extreme conditions.
2Reliability
If the microsystem uses a dense encapsulating package to protect against caustic wellbore fluid environment, then the reliability and chemical resistance are improved, but the transfer of environmental data (pressure, temperature, magnetic, and inertial) to the sensing elements deteriorates
Solution Approach 1:
The packaging system is segmented into protective outer shell and sensing interface membrane, allowing the outer shell to provide chemical resistance while the inner membrane enables sensor coupling.
Solution Approach 2:
A deformable membrane made of flexible material is used as the sensing interface. This thin film allows mechanical deformation under pressure while maintaining chemical resistance, enabling pressure sensing without compromising reliability in harsh environments.
3Measurement precision
If the microsystem uses conventional deployment methods (Smart pigs occupying entire pipeline diameter), then the diagnostic capability is improved, but the deployment cost and operational disruption deteriorate
Solution Approach 1:
The sensing and diagnostic functions are extracted from large conventional inspection devices and concentrated into a miniature autonomous microsystem. This extraction enables the same diagnostic capabilities with a dramatically reduced device size, allowing deployment through standard pipeline infrastructure without occupation of the entire pipeline diameter.
Solution Approach 2:
The functionality of large conventional diagnostic systems is replicated in a miniaturized autonomous microsystem format, achieving equivalent diagnostic capability with simplified deployment and reduced operational disruption.
4Adaptability or versatility
If the microsystem uses autonomous operation without external power connection, then the operational independence and adaptability are improved, but the power management complexity and operational lifetime deteriorate
Solution Approach 1:
The microsystem employs periodic wake-sleep cycles where the processor and sensors remain in low-power sleep mode between measurement intervals, activating only when data collection is required. This periodic operation dramatically reduces average power consumption while maintaining autonomous operational capability.
Solution Approach 2:
The microsystem includes integrated power management circuits that autonomously regulate power distribution, monitor battery status, and control wake-sleep cycles without external intervention, enabling independent operation while optimizing energy utilization.
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 ensures reliable operation in extreme environments, reduces deployment risks, and extends operational lifetime by optimizing power usage, enabling cost-effective and efficient data collection in fluid environments.
Implementation Method 1
a plurality of filler particles disposed in the internal space and configured to control a density of the autonomous microsystem in relation to the fluid
Implementation Method 2
The electronics is configured to sense and record one or more environmental conditions. The autonomous microsystem includes a packaging system that surrounds the electronics and the power source
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In various aspects, the present disclosure provides an example autonomous microsystem for immersion into a fluid. The autonomous microsystem includes electronics, a power source, and a packaging system that surrounds the electronics and the power source. The electronics can be configured to sense and record one or more environmental conditions. The packaging system may include a deformable shell that defines an internal space and a plurality of filler particles disposed in the internal space and configured to control a density of the autonomous microsystem in relation to the fluid. The filler particles may comprise a low-density material having a bulk density greater than or equal to about 100 kg/m3 and less than or equal to about 1,000 kg/m3 and have a packing density greater than or equal to about 1011/m3 and less than or equal to about 1021/m3.