Well Tool Internal Pressure Testing via Sensor Monitoring
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Solution Overview
Problem
Well tools are often manufactured and installed without adequate pressure testing due to the lack of availability of facilities for conducting external pressure tests, which can lead to defects such as missing, damaged, or improperly installed seals, and potential failures during operation.
Innovation Solution
A system and method for pressure testing well tools by applying internal pressure to a chamber within the tool, using a pressure sensor to monitor for leaks, eliminating the need for bulky external pressure test chambers and allowing for continuous monitoring during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external pressure testing facilities are used to pressure test well tools, then testing reliability is improved, but device complexity and cost increase
Solution Approach 1:
Instead of applying external pressure to the well tool chamber as in conventional testing, the patent applies internal pressure to the chamber from within. This inversion of the pressure application direction eliminates the need for complex external pressure chambers and testing facilities, while still achieving reliable detection of seal defects and chamber integrity issues.
Solution Approach 2:
The well tool's own pressure sensor is utilized to monitor the internal chamber pressure during testing. This self-service approach eliminates the need for external pressure sensors and control systems, simplifying the testing facility requirements while maintaining testing reliability through continuous pressure monitoring.
2Reliability
If external pressure chambers are used for testing, then pressure testing capability is improved, but portability and ease of operation worsen
Solution Approach 1:
By inverting the pressure application method from external to internal, the patent eliminates the requirement for bulky external pressure chambers. The internal pressure application can be achieved through simpler means such as injecting pressurized fluid through a valve, dramatically improving portability and ease of operation while maintaining full pressure testing capability.
Solution Approach 2:
The patent extracts the pressure testing function from the complex external facility context and integrates it into the well tool itself. By using the tool's internal components (valve, pressure sensor) to perform the testing, the method removes the dependency on external pressure chambers, making the testing process portable and easy to operate.
3Measurement precision
If comprehensive pressure testing is performed, then defect detection accuracy is improved, but testing time and cost increase
Solution Approach 1:
The well tool's integrated pressure sensor provides continuous real-time monitoring of internal chamber pressure during the testing process. This self-service monitoring capability enables comprehensive defect detection accuracy by detecting even minor pressure changes that indicate seal defects or chamber issues, while the automated nature of the process reduces testing time compared to manual external testing methods.
Solution Approach 2:
The pressure monitoring continues throughout the entire testing process without interruption, providing continuous data on chamber integrity. This continuous monitoring ensures high defect detection accuracy by capturing all pressure anomalies, while the uninterrupted process eliminates the need for multiple separate testing steps, thereby reducing overall testing time.
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
This approach effectively detects defects and potential failures in well tools without requiring expensive external testing facilities, ensuring the integrity of seals and preventing operational issues, while minimizing safety risks and operational costs.
Implementation Method 1
monitoring the pressure in the internal chamber using a pressure sensor in the internal chamber
Data Source
AI summary
A method of pressure testing a well tool can include applying positive or negative pressure to an internal chamber of the well tool, or determining a reference pressure, and monitoring the pressure in the internal chamber using a pressure sensor in the internal chamber. Another method can include applying pressure to an internal chamber of a well tool at a surface location, thereby creating a pressure differential in one direction across a seal, and installing the well tool in a well, thereby creating another pressure differential in a possibly opposite direction across the seal. A well system can include a well tool including an internal chamber, and a pressure sensor disposed in the chamber, whereby the pressure sensor detects pressure within the chamber.