Resin Sealed Sensor Port for Downhole Fluid Measurement
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Solution Overview
Problem
Existing systems for downhole sensors fail to effectively seal sensor ports from external environments while allowing for the measurement of fluid properties in wellbore completion processes, leading to potential contamination and inaccurate data collection.
Innovation Solution
A system and method involving a shroud and snorkel assembly with a sealed fluid communication channel, utilizing a resin coating for a water- and air-tight seal, which allows for flexible placement of sensors without the need for welding or electrical connections, ensuring accurate measurement of temperature, pressure, and other fluid properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods (welding, electrical connections) are used for sensor ports, then sealing reliability is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent replaces traditional mechanical sealing methods (welding, threading, electrical connections) with a polymer-based chemical sealing system. The polymer material is applied in a molten or pliable state and cures to form a sealed barrier, eliminating the need for complex mechanical assembly operations while maintaining sealing effectiveness in downhole environments.
Solution Approach 2:
The patent utilizes changes in the physical state of polymer material (from pliable/molten to cured/solid) to achieve sealing. By controlling temperature and curing parameters, the polymer transitions to a state that provides effective sealing without requiring complex mechanical fastening or connection systems.
2Reliability
If sensor ports are sealed to protect from contamination, then sensor protection is improved, but fluid communication capability deteriorates
Solution Approach 1:
The patent applies sealing material selectively around the periphery of the sensor port while leaving the central fluid communication pathway open. This localized application ensures that the seal protects the sensor housing and mounting structures without obstructing the fluid flow path, maintaining both protection and communication functionality.
Solution Approach 2:
The sealing system is divided into distinct functional zones: the polymer material seals the annular space between the sensor housing and port structure, while the central bore remains open for fluid communication. This segmentation allows independent optimization of sealing and flow characteristics.
3Strength
If rigid sealing structures are used for sensor ports, then sealing strength is improved, but adaptability and ease of installation deteriorate
Solution Approach 1:
The patent employs polymer materials that exhibit flexible, pliable characteristics during installation, allowing the sealing compound to conform to various sensor housing geometries and port configurations. Once cured, the polymer provides sufficient sealing strength while the initial flexibility enables broad adaptability during the installation process.
Data Source
AI summary
An array of sensors provided on the outside of a tubular string for measuring a property within the tubular string. The array of sensors may include a plurality of connected sensors, wherein at least one of the plurality of connected sensors is at least partially encompassed in a shroud. A snorkel line may extend from the shroud, the snorkel line capable of coupling with a sensor port in a tubular of the tubular string. The snorkel line may establish fluid communication between one of the sensors at least partially encompassed in the shroud and a corresponding sensor port of a tubular in the tubular string.