Spoolable Sensor Array for Downhole Measurement

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Solution Overview

Problem

Current downhole sensor technologies face challenges in effectively measuring properties like pressure, temperature, and flow rate within wellbores, especially in complex wellbore environments with varying lengths and limited sensor flexibility, due to the need for precise alignment and difficulty in stretching sensors to accommodate variable tubular string lengths.

Innovation Solution

A spoolable array of sensors connected via a conductive line, which can be deployed along with a tubular string and coupled to its exterior, using clamps or straps, with flow ports and shrouds to measure internal fluid properties without direct exposure to production zones, allowing for flexible placement and accurate data collection across multiple production zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional rigid sensor arrays are used in wellbores, then measurement precision can be maintained, but adaptability to varying wellbore lengths and configurations deteriorates

Engineering Contradiction:

Improvemeasurement precisionVSAvoidadaptability to varying wellbore lengths

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent employs flexible sensor arrays that can be stretched and conform to varying wellbore tubular string lengths. The sensor array is designed with flexible connections between individual sensors, allowing it to adapt to different wellbore configurations while maintaining measurement capabilities across multiple production zones.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sensor array is designed to be dynamically adjustable in length and configuration. The array can be stretched to accommodate longer tubular strings and can be deployed in different wellbore configurations, transforming from a rigid structure to a flexible, adaptable measurement system that maintains precision across varying conditions.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If sensors are stretched to accommodate variable tubular string lengths, then adaptability improves, but measurement precision and reliability deteriorate

Engineering Contradiction:

Improveadaptability to tubular string lengthsVSAvoidmeasurement reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The sensor array is divided into multiple discrete sensor elements connected by flexible linkages. This segmentation allows each sensor to maintain its measurement integrity while the overall array can be stretched and configured to match varying tubular string lengths without compromising individual sensor reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible connections between sensors are designed to accommodate stretching while maintaining electrical and mechanical integrity. The flexible structure allows the array to conform to different wellbore configurations without damaging the sensors or degrading measurement quality.

Inventive Principle:

Principle #30Flexible shells and thin films

3Measurement precision

If precise alignment of sensors with flow ports is required, then measurement precision improves, but device complexity and ease of operation worsen

Engineering Contradiction:

Improvemeasurement precisionVSAvoidalignment complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The flexible sensor array can be stretched and positioned to naturally align with flow ports along the tubular string. The flexibility eliminates the need for complex rigid alignment mechanisms, as the array can conform to the wellbore geometry and achieve proper sensor-to-flow-port alignment through deployment tension alone.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sensor array achieves alignment with flow ports through its own deployment and stretching process. As the array is deployed and stretched along the tubular string, the sensors automatically position themselves relative to the flow ports, eliminating the need for external alignment tools or complex positioning mechanisms.

Inventive Principle:

Principle #25Self-service

4Productivity

If multiple sensors are deployed across production zones, then measurement capability improves, but device complexity worsens

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidsensor array complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple individual sensors are merged into a single integrated flexible array structure. This combining approach allows the system to maintain multiple measurement capabilities across different production zones while presenting a unified, manageable deployment unit that reduces operational complexity compared to deploying and managing separate sensor systems.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11499416B2Determining downhole properties with sensor array

Publication Date: 2022.11.15 HALLIBURTON ENERGY SERVICES INC

AI summary

A spoolable array of sensors may be deployed within a wellbore and external a tubular string for measuring properties of a fluid in the central flow passage of the tubular string. A flow port may be made in the tubular string passing from the central flow passage to the external surface. Sensors of the spoolable array of sensors may be covered with a shroud and placed proximate the flow port, or such sensors may be isolated in a zone with packers along with the flow port. The spoolable array of sensors may additionally obtain pressure data to calculate a flow rate from a production zone. The spoolable array of sensors may also be employed in a non-flowing wellbore for monitoring nearby wellbores.