Sensor-Integrated Frac Plug for Downhole Data Retrieval
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Solution Overview
Problem
Existing fracturing operations in well drilling face challenges with external gauges and control lines that are prone to damage and orientation issues, and dummy frac plugs provide limited functionality.
Innovation Solution
Integrate electronic sensors, a digital storage device, and a power supply into frac plugs to collect and store data on fracturing operations, enabling data retrieval through inductive coupling, physical retrieval, or wireless transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external gauges and control lines are deployed for fracturing operations, then data collection capability is provided, but the system becomes vulnerable to damage and orientation issues
Solution Approach 1:
The patent combines sensors, data storage, and data processing capabilities directly into the frac plug assembly, eliminating the need for separate external gauges and control lines. This integration protects the sensing elements from damage during installation and operation, while maintaining reliable data collection throughout the fracturing process.
Solution Approach 2:
The frac plug serves as an intermediary device that both isolates the formation during fracturing and protects the integrated sensors from external damage. The plug's structural design shields the embedded electronics and sensing elements while still allowing them to measure pressure, temperature, and other fracturing parameters accurately.
2Adaptability or versatility
If dummy frac plugs are used for limited operations, then basic data collection is possible, but functionality remains very limited
Solution Approach 1:
The frac plug is designed with multi-functionality, serving both as a fracturing isolation device and as a comprehensive data collection platform. The integrated sensors can measure multiple parameters including pressure, temperature, and flow characteristics, while the data storage and processing capabilities enable various operational modes including fracturing, production monitoring, and diagnostic operations.
Solution Approach 2:
The system incorporates dynamic data collection and processing capabilities that adapt to different operational phases. Sensors continuously monitor changing conditions during fracturing and production, with data storage and retrieval mechanisms that accommodate varying operational requirements, enabling the same device to serve multiple purposes throughout the well lifecycle.
3Loss of information
If expensive external gauges with control lines are deployed, then comprehensive data collection is achieved, but installation cost and complexity increase
Solution Approach 1:
By merging sensors, data storage, and processing capabilities into a single integrated frac plug assembly, the system eliminates the need for separate control lines and external gauge installations. This reduces installation complexity while maintaining complete data collection capabilities throughout the fracturing operation.
Solution Approach 2:
The frac plug performs self-service data collection and storage without requiring external control lines or additional installation infrastructure. The integrated system automatically captures, stores, and preserves fracturing data, eliminating the need for complex external monitoring infrastructure and reducing both installation cost and complexity.
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 cost-effective and reliable data collection during fracturing operations without damaging external gauges, allowing for efficient data retrieval and analysis.
Implementation Method 1
a sensor coupled to the plug for collecting data within the cased borehole
Implementation Method 2
data retrieval through inductive coupling
Data Source
AI summary
A technique facilitates collecting data, related to a fracturing, run-in-hole, or pull-out-of hole operation. A frac plug is provided with electronics for obtaining the desired information related to the operation. For example, the frac plug may be constructed with electronic sensors, a digital storage device, and a power supply or other power related equipment. Depending on the application, the frac plug may be a composite frac plug, degradable frac plug, dummy frac plug, or other suitable frac plug. Retrieval of the information obtained may be done via coupling with an associated device, e.g. inductive or physical coupling, by utilizing a broadcast transmitter/receiver, by physical retrieval of the storage device, or by physical retrieval of the dummy frac plug.