US20240159143A1 - Multi-sensor downhole gauge - Google Patents
Multi-sensor downhole gauge Download PDFInfo
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- US20240159143A1 US20240159143A1 US18/508,813 US202318508813A US2024159143A1 US 20240159143 A1 US20240159143 A1 US 20240159143A1 US 202318508813 A US202318508813 A US 202318508813A US 2024159143 A1 US2024159143 A1 US 2024159143A1
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- gauge
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/06—Measuring temperature or pressure
- E21B47/07—Temperature
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/01—Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like
Definitions
- FIG. 1 illustrates a well system, including a sensor array having one or more downhole gauges designed, manufactured and/or operated according to one embodiment of the disclosure
- FIGS. 2 A through 2 E illustrate different views of one embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure
- FIGS. 3 A through 3 E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure
- FIGS. 4 A through 4 E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure
- FIGS. 5 A through 5 E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure
- FIGS. 6 A through 6 E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- FIGS. 7 A through 7 E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- connection Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described.
- use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation.
- any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis.
- use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
- the term “substantially” in reference to a given parameter means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances.
- a parameter that is substantially met may be at least about 90% met, at least about 95% met, at least about 99% met, or even at least about 100% met.
- a downhole gauge e.g., within a gauge housing of the downhole gauge
- a Permanent Downhole Gauge PDG
- downhole gauge packaging has been limited to two pressure/temperature sensor sets. This design practice limits the downhole gauge to either both sensors monitoring the same pressure/temperature source (e.g., redundant measurement) or the downhole gauge can monitor two different pressure/temperature sources with two single sensors.
- one or more housings are added adjacent (e.g., radially offset and either axially aligned or axially offset, and coupled via a block splitter) thereto or there below (e.g., axially offset and radially offset or radially aligned) to obtain the additional pressure/temperature measurements.
- Adding sensors in this manner either requires the gauge mandrel, or other host tubular, to increase in OD to protect the downhole gauge or the gauge mandrel, or the other host tubular to be considerably longer.
- TEC Tubing Encapsulated Conductor
- the present disclosure teaches one skilled in the art how to package three or more sensors/sensor sets into a single gauge housing (e.g., single cylindrical gauge housing) of a downhole gauge, which heretofore was not feasible.
- This new three or more sensor downhole gauge design reduces the overall size of the downhole gauge, as well reduces the number of potential leak paths and/or failure points.
- the new three or more sensor downhole gauge design may employ a newly developed single board for each of the three or more sensor, each single board including both the communications electronics and sensor electronics in a Hybrid ASIC (e.g., collectively forming a sensor set).
- Hybrid ASIC e.g., collectively forming a sensor set.
- This new Hybrid ASIC has allowed the downhole gauge to achieve an acceptable length, all the while including three or more sensors.
- a single TEC may communicate with each of the three or more sensors of the downhole gauge.
- the new three or more sensor downhole gauge design may be a splitter less design, and thus not employ a block splitter to accommodate the multiple radially offset downhole gauges.
- the new third (e.g., or more) sensor/sensor set may be used for a variety of different purposes.
- the new third (e.g., or more) sensor/sensor set is just another pressure and/or temperature sensor.
- the new third (e.g., or more) sensor/sensor set is a water cut sensor, phase change sensor (e.g., steam break through sensor), an accelerometer (e.g., vibration sensor) or gyroscope (e.g., orientation sensor).
- the new third (e.g., or more) sensor/sensor set is a position sensor, as might be used for determining a position of an interval control valve (ICV).
- IOV interval control valve
- the new third (e.g., or more) sensor/sensor set is a CO 2 , H 2 or H 2 S sensor, among others. Notwithstanding, the new third (e.g., or more) sensor/sensor set should not be limited to any specific sensor, and thus may include many different pressure and/or temperature sensors.
- the sensor array 102 may include one or more downhole gauges 105 interconnected by lengths of wellbore conveyance 110 .
- the wellbore conveyance 110 is a cable.
- the sensor array 102 may include any suitable number of downhole gauges 105 .
- the sensor array 102 may include between ten and one hundred downhole gauges 105 .
- the downhole gauges 105 may each be configured to detect at least one of a pressure and/or temperature, among other measurements.
- some or all of the downhole gauges 105 in the sensor array 102 may each be configured to at least substantially simultaneously (e.g., at substantially the same time, in the same time interval) detect at least one of a pressure and/or a temperature in a wellbore and relay those sensed values, such that a continuous profile of conditions in the wellbore relating to such sensed values may be provided to an operator monitoring wellbore conditions.
- the sensor array 102 in the illustrated embodiment, is deployed within a wellbore 115 , e.g., a well for the production of oil, natural gas, water, or another subterranean resource.
- Each downhole gauge 105 of the sensor array 102 may be used to collect data related to at least one of a pressure and/or a temperature, among others, at a particular location within the wellbore 115 .
- each downhole gauge 105 of the sensor array 102 may collect data relating to conditions within a string of tubular components (e.g., a production string) positioned in the wellbore 115 , data relating to conditions in an annulus between the string and the wellbore 115 itself, or combinations thereof, again among others.
- ones of the downhole gauges 105 of the sensor array 102 may be positioned outside of the production string in the wellbore annulus between the string and a casing or liner string adjacent the wall of the wellbore 115 .
- the ones of the downhole gauges 105 of the sensor array 102 may be placed in direct communication with an interior of the production string in the wellbore.
- ones of the downhole gauges 105 of the sensor array 102 may be coupled to the outside of the production string and one or more apertures in the production string may place the ones of the downhole gauge 105 of the sensor array 102 in communication with the interior of the production string (e.g., in direct communication with pressure and/or temperature inside the production string via the apertures).
- Data from each individual downhole gauge 105 may be combined to provide information about a pressure and/or temperature profile within the wellbore 115 along a length of the wellbore 115 along which the sensor array 102 is deployed.
- the downhole gauge 200 in the illustrated embodiment, includes a gauge housing 210 .
- the gauge housing 210 in one or more embodiments, may comprise a single gauge housing.
- the gauge housing 210 may comprise separate gauge housing sections that cooperate (e.g., are interconnected) to form a single gauge housing.
- the gauge housing 210 includes five separate interconnected gauge housing sections 210 a , 210 b , 210 c , 210 d , 210 e .
- the first gauge housing section 210 a is a tubing encapsulated conductor (TEC) housing
- the second gauge housing section 210 b is a first pressure housing
- the third gauge housing section 210 c is a sensor manifold housing
- the fourth gauge housing section 210 d is a second pressure housing
- the fifth gauge housing section 210 e is a hydraulic line housing.
- the downhole gauge 200 additionally includes a TEC 220 coupled with a first end 215 a of the gauge housing 210 (e.g., the first gauge housing section 210 a ), as well as a hydraulic line 230 (e.g., coupled to a remote pressure source) coupled with a second end 215 b of the gauge housing 210 (e.g., the fifth gauge housing section 210 e ).
- the TEC 220 in the illustrated embodiment, terminates within the gauge housing 210 proximate a TEC connection 225 coupled with the first gauge housing section 210 a .
- the hydraulic line 230 terminates at a hydraulic line connection 235 coupled with the fifth gauge housing section 210 e.
- the downhole gauge 200 includes three or more sensors located within the gauge housing 210 .
- the downhole gauge 200 includes a first sensor 240 , a second sensor 260 , and a third sensor 280 , all located within an interior of the gauge housing 210 .
- one or more of the first sensor 240 , second sensor 260 , and third sensor 280 are sensor sets, and thus include the communication electronics and sensor electronics on a single board.
- the first sensor 240 may include a connection 245 (e.g., a metal-to-metal seal, such as an olive seal), which may allow the first sensor 240 to measure the pressure and/or temperature in an inside diameter (ID) of tubing that the downhole gauge 200 is coupled.
- a connection 245 e.g., a metal-to-metal seal, such as an olive seal
- the second sensor 260 may fail to include a connection, which may allow the second sensor 260 to measure the pressure and/or temperature in an annulus surrounding the tubing that the downhole gauge 200 is coupled.
- the third sensor 280 may be directly coupled to the hydraulic line 230 , which may allow the third sensor 280 to measure the pressure and/or temperature of a remote zone.
- first, second and third sensors 240 , 260 , 280 are each pressure and/or temperature sensors, other embodiments may exist wherein one or more of the first, second and third sensors 240 , 260 , 280 are another type of sensor, as discussed above.
- the fifth gauge housing section 210 e is a thinner walled tubular 205 . Accordingly, in at least one embodiment, the fifth gauge housing section 210 e may only be rated for up to about 1000 Bar (e.g., approximately 15K psi). Furthermore, as shown in FIGS. 2 A through 2 E , seals 242 , 262 , 282 , may be used to separate the first sensor 240 , second sensor 260 , and third sensor 280 from other features within the gauge housing 210 , including from one another. Furthermore, while the embodiment of FIGS. 2 A through 2 E illustrate only a first sensor 240 , a second sensor 260 and a third sensor 280 , other embodiments may exist wherein a fourth sensor, fifth sensor, etc. may be included within the gauge housing 210 .
- FIGS. 3 A through 3 E illustrated are different views of an alternative embodiment of a downhole gauge 300 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- the downhole gauge 300 of FIGS. 3 A through 3 E is similar in many respects to the downhole gauge 200 of FIGS. 2 A through 2 E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features.
- the downhole gauge 300 differs, for the most part, from the downhole gauge 200 , in that the downhole gauge 300 employs a thicker walled 305 fifth gauge housing second 310 e .
- the thicker walled 305 fifth gauge housing section 310 e along with optional high pressure welds, allows the downhole gauge 300 to accommodate wells with higher hydrostatic pressures. Accordingly, the downhole gauge 300 of FIGS. 3 A through 3 E may be rated for pressures greater than 1000 Bar (e.g., greater than approximately 15K psi), including being rated for pressures above 1700 Bar (e.g., greater than approximately 25K psi) and/or above 2400 Bar (e.g., greater than approximately 35K psi).
- FIGS. 4 A through 4 E illustrated are different views of an alternative embodiment of a downhole gauge 400 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- the downhole gauge 400 of FIGS. 4 A through 4 E is similar in many respects to the downhole gauge 300 of FIGS. 3 A through 3 E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features.
- the downhole gauge 400 differs, for the most part, from the downhole gauge 300 , in that the downhole gauge 400 employs a fourth sensor 440 .
- the fourth sensor 440 as discussed above, may be any type of sensor and remain within the scope of the disclosure.
- the fourth sensor 440 could be another pressure and/or temperature sensor that is configured to measure the pressure and/or temperature of another location, or alternatively could be a redundant pressure and/or temperature sensor configured to measure the pressure and/or temperature of an existing location.
- the fourth sensor 440 could be a different type of sensor, and thus not configured to measure pressure and/or temperature.
- FIGS. 4 A through 4 E show the fourth sensor 440 positioned to the left of the first sensor 240
- the fourth sensor 440 could be located at any other position within the gauge housing 210 and remain within the scope of the disclosure.
- the fourth sensor 440 is mounted on a chassis 444 .
- This chassis 444 is coupled to a chassis 244 of the first pressure and/or temperature sensor 240 , and installed in the ID of the gauge housing 210 .
- the fourth sensor 440 could also be mounted on a chassis which is threaded into a portion of the gauge housing 210 wall.
- one chassis could also be designed such that two or more sensors could be mounted together.
- FIGS. 5 A through 5 E illustrated are different views of an alternative embodiment of a downhole gauge 500 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- the downhole gauge 500 of FIGS. 5 A through 5 E is similar in many respects to the downhole gauge 300 of FIGS. 3 A through 3 E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features.
- the downhole gauge 500 differs, for the most part, from the downhole gauge 300 , in that the downhole gauge 500 employs its second sensor 260 for measuring the pressure and/or temperature of a remote zone, and uses the third sensor 280 (e.g., now in a sixth gauge housing section 510 a ) for measuring the annulus pressure.
- the downhole gauge 500 may include an internal wire passageway 550 , such that a wire (e.g., TEC) may traverse the length of the downhole gauge 500 .
- a wire e.g., TEC
- the downhole gauge 500 may include a second TEC 520 and associated second TEC connection 525 .
- FIGS. 6 A through 6 E illustrated are different views of an alternative embodiment of a downhole gauge 600 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- the downhole gauge 600 of FIGS. 6 A through 6 E is similar in many respects to the downhole gauge 500 of FIGS. 5 A through 5 E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features.
- the downhole gauge 600 differs, for the most part, from the downhole gauge 500 , in that the downhole gauge 600 employs simple holes 610 in the gauge housing 210 (e.g., holes extending through the sidewall thickness of the gauge housing 210 in either of the fifth gauge housing section 210 e or sixth gauge housing section 510 a ) to provide access to fluid within the annulus.
- the downhole gauge 500 employs a sensor manifold housing for its fifth gauge housing section 210 e.
- FIGS. 7 A through 7 E illustrated are different views of an alternative embodiment of a downhole gauge 700 designed, manufactured and/or operated according to one or more embodiments of the disclosure.
- the downhole gauge 700 of FIGS. 7 A through 7 E is similar in many respects to the downhole gauge 500 of FIGS. 5 A through 5 E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features.
- the downhole gauge 700 differs, for the most part, from the downhole gauge 500 , in that the downhole gauge 700 employs a fourth sensor 740 .
- the fourth sensor 740 as discussed above, may be any type of sensor and remain within the scope of the disclosure.
- the fourth sensor 740 could be another pressure and/or temperature sensor that is configured to measure the pressure and/or temperature of another location, or alternatively could be a redundant pressure and/or temperature sensor configured to measure the pressure and/or temperature of an existing location.
- the fourth sensor 740 could be a different type of sensor other than a pressure and/or temperature sensor.
- FIGS. 7 A through 7 E show the fourth sensor 740 positioned to the left of the first sensor 240
- the fourth sensor 740 could be located at any other position within the gauge housing 210 and remain within the scope of the disclosure.
- a downhole gauge according to the present disclosure has many benefits. For example, a downhole gauge with three or more sensors (e.g., three or more pressure and/or temperature sensors) minimizes TEC terminations, minimizes downhole gauge length (e.g., vs adding downhole gauge below) and minimizes potential leak paths.
- a downhole gauge with three or more sensors e.g., three or more pressure and/or temperature sensors
- the downhole gauge with hydraulic connection at the bottom eliminates the need to machine hydraulic channels in the gauge mandrel to enable the downhole gauge to monitor a remote zone, reduces gauge mandrel complexity, and minimizes gauge mandrel OD.
- a downhole gauge with three or more sensors e.g., three or more pressure and/or temperature sensors
- a downhole gauge with three pressure and/or temperature sensors, and the option to add additional sensors, along with a TEC feedthrough enables multi-drop capability.
- a downhole gauge for use in a wellbore, the downhole gauge including: 1) a gauge housing, the gauge housing having a first end and a second opposing end; and 2) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
- a well system including: 1) a wellbore extending through one or more subterranean formations; 2) a tubular located within the wellbore; and 3) a downhole gauge coupled with the tubular within the wellbore, the downhole gauge including: a) a gauge housing, the gauge housing having a first end and a second opposing end; and b) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
- a method including: 1) positioning a tubular within a wellbore extending through one or more subterranean formations, the tubular having a downhole gauge coupled therewith, the downhole gauge including: a) a gauge housing, the gauge housing having a first end and a second opposing end; and b) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end; and 2) measuring one or more properties within the wellbore using the first, second and third sensors located within the interior of the gauge housing.
- aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: further including a tubing encapsulated conductor (TEC) coupled to the first end of the gauge housing using a tubing encapsulated conductor (TEC) connection. Element 2: wherein the tubing encapsulated conductor (TEC) is a first tubing encapsulated conductor (TEC), and further including a second tubing encapsulated conductor (TEC) coupled to the second end of the gauge housing using a second tubing encapsulated conductor (TEC) connection.
- TEC tubing encapsulated conductor
- TEC tubing encapsulated conductor
- Element 3 further including one or more internal wire passageways extending from the first and second opposing ends of the gauge housing, the one or more internal wire passageways configured to couple the first tubing encapsulated conductor (TEC) and the second tubing encapsulated conductor (TEC).
- Element 4 wherein the gauge housing includes a plurality of interconnected gauge housing sections.
- the first sensor is a first pressure and/or temperature sensor, the first pressure and/or temperature sensor configured to measure a first pressure and/or temperature in an inside diameter (ID) of tubing that the downhole gauge is coupled.
- Element 6 wherein the second sensor is a second pressure and/or temperature sensor, the second pressure and/or temperature sensor configured to measure a second pressure and/or temperature in an annulus surrounding the tubing that the downhole gauge is coupled.
- Element 7 wherein the third sensor is a third pressure and/or temperature sensor, the third pressure and/or temperature sensor configured to measure a third pressure and/or temperature of a remote zone.
- Element 8 further including a fourth sensor located within the interior the gauge housing, the fourth sensor not configured to measure pressure and/or temperature.
- one or more of the first, second and third sensors is a sensor set, each sensor set including communication electronics and sensor electronics on a single board.
- the downhole gauge is a first downhole gauge, and further including a second downhole gauge coupled with the tubular within the wellbore, the first and second downhole gauges forming a sensor array, the second downhole gauge including: i) a second gauge housing, the second gauge housing having opposing ends; and ii) a second set of first, second and third sensors located within an interior of the second gauge housing between the opposing ends.
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Abstract
Provided is a downhole gauge for use in a wellbore, a well system, and a method. The downhole gauge, in one aspect, includes a gauge housing, the gauge housing having a first end and a second opposing end. The downhole gauge, according to this aspect, further includes first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
Description
- This application claims the benefit of U.S. Provisional Application Ser. No. 63/425,349, filed on Nov. 15, 2022, entitled “MULTI-SENSOR PERMANENT DOWNHOLE GAUGE,” commonly assigned with this application and incorporated herein by reference in its entirety.
- In some oil and gas production environments, it may be desirable to collect data from downhole sensors.
- Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
-
FIG. 1 illustrates a well system, including a sensor array having one or more downhole gauges designed, manufactured and/or operated according to one embodiment of the disclosure; -
FIGS. 2A through 2E illustrate different views of one embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure; -
FIGS. 3A through 3E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure; -
FIGS. 4A through 4E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure; -
FIGS. 5A through 5E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure; -
FIGS. 6A through 6E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure; and -
FIGS. 7A through 7E illustrate different views of an alternative embodiment of a downhole gauge designed, manufactured and/or operated according to one or more embodiments of the disclosure. - In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms.
- Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.
- Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” “downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.
- As used herein, the term “substantially” in reference to a given parameter means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. For example, a parameter that is substantially met may be at least about 90% met, at least about 95% met, at least about 99% met, or even at least about 100% met.
- It is often most efficient to package pressure and/or temperature sensors into a downhole gauge (e.g., within a gauge housing of the downhole gauge), such as a Permanent Downhole Gauge (PDG), for monitoring downhole (e.g., reservoir) pressures and/or temperatures, among other measurements. Historically downhole gauge packaging has been limited to two pressure/temperature sensor sets. This design practice limits the downhole gauge to either both sensors monitoring the same pressure/temperature source (e.g., redundant measurement) or the downhole gauge can monitor two different pressure/temperature sources with two single sensors. Historically, in those situations where a third pressure source is desired, or redundant sensor sets for each pressure/temperature source is desired, one or more housings are added adjacent (e.g., radially offset and either axially aligned or axially offset, and coupled via a block splitter) thereto or there below (e.g., axially offset and radially offset or radially aligned) to obtain the additional pressure/temperature measurements. Adding sensors in this manner either requires the gauge mandrel, or other host tubular, to increase in OD to protect the downhole gauge or the gauge mandrel, or the other host tubular to be considerably longer. Additionally, when downhole gauges are axially added together, a short segment of Tubing Encapsulated Conductor (TEC) is required to connect the downhole gauges. Each TEC connection adds a potential leak point to the downhole gauges, which is undesirable.
- The present disclosure teaches one skilled in the art how to package three or more sensors/sensor sets into a single gauge housing (e.g., single cylindrical gauge housing) of a downhole gauge, which heretofore was not feasible. This new three or more sensor downhole gauge design reduces the overall size of the downhole gauge, as well reduces the number of potential leak paths and/or failure points. Moreover, the new three or more sensor downhole gauge design may employ a newly developed single board for each of the three or more sensor, each single board including both the communications electronics and sensor electronics in a Hybrid ASIC (e.g., collectively forming a sensor set). This new Hybrid ASIC has allowed the downhole gauge to achieve an acceptable length, all the while including three or more sensors. Accordingly, in one or more embodiments a single TEC (e.g., single TEC path) may communicate with each of the three or more sensors of the downhole gauge. Moreover, the new three or more sensor downhole gauge design may be a splitter less design, and thus not employ a block splitter to accommodate the multiple radially offset downhole gauges.
- The new third (e.g., or more) sensor/sensor set may be used for a variety of different purposes. In at least one embodiment, the new third (e.g., or more) sensor/sensor set is just another pressure and/or temperature sensor. In another embodiment, the new third (e.g., or more) sensor/sensor set is a water cut sensor, phase change sensor (e.g., steam break through sensor), an accelerometer (e.g., vibration sensor) or gyroscope (e.g., orientation sensor). In another embodiment, the new third (e.g., or more) sensor/sensor set is a position sensor, as might be used for determining a position of an interval control valve (ICV). In yet another embodiment, the new third (e.g., or more) sensor/sensor set is a CO2, H2 or H2S sensor, among others. Notwithstanding, the new third (e.g., or more) sensor/sensor set should not be limited to any specific sensor, and thus may include many different pressure and/or temperature sensors.
- Referring now to
FIG. 1 , there is shown one embodiment of awell system 100, including asensor array 102 having one or more downhole gauges designed, manufactured and/or operated according to one embodiment of the disclosure. Thesensor array 102, in some embodiments, may include one ormore downhole gauges 105 interconnected by lengths ofwellbore conveyance 110. In certain embodiments, thewellbore conveyance 110 is a cable. Thesensor array 102 may include any suitable number ofdownhole gauges 105. For example, in some embodiments of the disclosure, thesensor array 102 may include between ten and one hundreddownhole gauges 105. Thedownhole gauges 105 may each be configured to detect at least one of a pressure and/or temperature, among other measurements. For example, some or all of thedownhole gauges 105 in the sensor array 102 (e.g., a distributed sensor array) may each be configured to at least substantially simultaneously (e.g., at substantially the same time, in the same time interval) detect at least one of a pressure and/or a temperature in a wellbore and relay those sensed values, such that a continuous profile of conditions in the wellbore relating to such sensed values may be provided to an operator monitoring wellbore conditions. - The
sensor array 102, in the illustrated embodiment, is deployed within awellbore 115, e.g., a well for the production of oil, natural gas, water, or another subterranean resource. Eachdownhole gauge 105 of thesensor array 102 may be used to collect data related to at least one of a pressure and/or a temperature, among others, at a particular location within thewellbore 115. For example, eachdownhole gauge 105 of thesensor array 102 may collect data relating to conditions within a string of tubular components (e.g., a production string) positioned in thewellbore 115, data relating to conditions in an annulus between the string and thewellbore 115 itself, or combinations thereof, again among others. For example, ones of thedownhole gauges 105 of thesensor array 102 may be positioned outside of the production string in the wellbore annulus between the string and a casing or liner string adjacent the wall of thewellbore 115. - In some embodiments, the ones of the
downhole gauges 105 of thesensor array 102 may be placed in direct communication with an interior of the production string in the wellbore. For example, ones of thedownhole gauges 105 of thesensor array 102 may be coupled to the outside of the production string and one or more apertures in the production string may place the ones of thedownhole gauge 105 of thesensor array 102 in communication with the interior of the production string (e.g., in direct communication with pressure and/or temperature inside the production string via the apertures). Data from each individualdownhole gauge 105 may be combined to provide information about a pressure and/or temperature profile within thewellbore 115 along a length of thewellbore 115 along which thesensor array 102 is deployed. - Turning to
FIGS. 2A through 2E , illustrated are different views of one embodiment of adownhole gauge 200 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 200, in the illustrated embodiment, includes agauge housing 210. Thegauge housing 210, in one or more embodiments, may comprise a single gauge housing. In yet another embodiment, thegauge housing 210 may comprise separate gauge housing sections that cooperate (e.g., are interconnected) to form a single gauge housing. For example, in the illustrated embodiment ofFIGS. 2A through 2E , thegauge housing 210 includes five separate interconnectedgauge housing sections gauge housing section 210 a is a tubing encapsulated conductor (TEC) housing, the secondgauge housing section 210 b is a first pressure housing, the thirdgauge housing section 210 c is a sensor manifold housing, the fourthgauge housing section 210 d is a second pressure housing, and the fifthgauge housing section 210 e is a hydraulic line housing. - The
downhole gauge 200, in the illustrated embodiment, additionally includes aTEC 220 coupled with afirst end 215 a of the gauge housing 210 (e.g., the firstgauge housing section 210 a), as well as a hydraulic line 230 (e.g., coupled to a remote pressure source) coupled with asecond end 215 b of the gauge housing 210 (e.g., the fifthgauge housing section 210 e). TheTEC 220, in the illustrated embodiment, terminates within thegauge housing 210 proximate aTEC connection 225 coupled with the firstgauge housing section 210 a. Similarly, thehydraulic line 230 terminates at ahydraulic line connection 235 coupled with the fifthgauge housing section 210 e. - In accordance with one embodiment of the disclosure, the
downhole gauge 200 includes three or more sensors located within thegauge housing 210. For example, in the illustrated embodiment ofFIGS. 2A through 2E , thedownhole gauge 200 includes afirst sensor 240, asecond sensor 260, and athird sensor 280, all located within an interior of thegauge housing 210. In at least one embodiment, one or more of thefirst sensor 240,second sensor 260, andthird sensor 280 are sensor sets, and thus include the communication electronics and sensor electronics on a single board. - As shown in
FIG. 2C , thefirst sensor 240 may include a connection 245 (e.g., a metal-to-metal seal, such as an olive seal), which may allow thefirst sensor 240 to measure the pressure and/or temperature in an inside diameter (ID) of tubing that thedownhole gauge 200 is coupled. In contrast, as shown inFIG. 2D , thesecond sensor 260 may fail to include a connection, which may allow thesecond sensor 260 to measure the pressure and/or temperature in an annulus surrounding the tubing that thedownhole gauge 200 is coupled. Furthermore, as shown inFIG. 2E , thethird sensor 280 may be directly coupled to thehydraulic line 230, which may allow thethird sensor 280 to measure the pressure and/or temperature of a remote zone. While the first, second andthird sensors third sensors - In the illustrated embodiment of
FIGS. 2A through 2E , the fifthgauge housing section 210 e is a thinnerwalled tubular 205. Accordingly, in at least one embodiment, the fifthgauge housing section 210 e may only be rated for up to about 1000 Bar (e.g., approximately 15K psi). Furthermore, as shown inFIGS. 2A through 2E , seals 242, 262, 282, may be used to separate thefirst sensor 240,second sensor 260, andthird sensor 280 from other features within thegauge housing 210, including from one another. Furthermore, while the embodiment ofFIGS. 2A through 2E illustrate only afirst sensor 240, asecond sensor 260 and athird sensor 280, other embodiments may exist wherein a fourth sensor, fifth sensor, etc. may be included within thegauge housing 210. - Turning to
FIGS. 3A through 3E , illustrated are different views of an alternative embodiment of adownhole gauge 300 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 300 ofFIGS. 3A through 3E is similar in many respects to thedownhole gauge 200 ofFIGS. 2A through 2E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features. Thedownhole gauge 300 differs, for the most part, from thedownhole gauge 200, in that thedownhole gauge 300 employs a thicker walled 305 fifth gauge housing second 310 e. The thicker walled 305 fifthgauge housing section 310 e, along with optional high pressure welds, allows thedownhole gauge 300 to accommodate wells with higher hydrostatic pressures. Accordingly, thedownhole gauge 300 ofFIGS. 3A through 3E may be rated for pressures greater than 1000 Bar (e.g., greater than approximately 15K psi), including being rated for pressures above 1700 Bar (e.g., greater than approximately 25K psi) and/or above 2400 Bar (e.g., greater than approximately 35K psi). - Turning to
FIGS. 4A through 4E , illustrated are different views of an alternative embodiment of adownhole gauge 400 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 400 ofFIGS. 4A through 4E is similar in many respects to thedownhole gauge 300 ofFIGS. 3A through 3E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features. Thedownhole gauge 400 differs, for the most part, from thedownhole gauge 300, in that thedownhole gauge 400 employs afourth sensor 440. Thefourth sensor 440, as discussed above, may be any type of sensor and remain within the scope of the disclosure. For instance, thefourth sensor 440 could be another pressure and/or temperature sensor that is configured to measure the pressure and/or temperature of another location, or alternatively could be a redundant pressure and/or temperature sensor configured to measure the pressure and/or temperature of an existing location. Alternatively, thefourth sensor 440 could be a different type of sensor, and thus not configured to measure pressure and/or temperature. Moreover, whileFIGS. 4A through 4E show thefourth sensor 440 positioned to the left of thefirst sensor 240, thefourth sensor 440 could be located at any other position within thegauge housing 210 and remain within the scope of the disclosure. - In the embodiment of
FIGS. 4A through 4E , thefourth sensor 440 is mounted on achassis 444. Thischassis 444 is coupled to achassis 244 of the first pressure and/ortemperature sensor 240, and installed in the ID of thegauge housing 210. Thefourth sensor 440 could also be mounted on a chassis which is threaded into a portion of thegauge housing 210 wall. Furthermore, one chassis could also be designed such that two or more sensors could be mounted together. - Turning to
FIGS. 5A through 5E , illustrated are different views of an alternative embodiment of adownhole gauge 500 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 500 ofFIGS. 5A through 5E is similar in many respects to thedownhole gauge 300 ofFIGS. 3A through 3E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features. Thedownhole gauge 500 differs, for the most part, from thedownhole gauge 300, in that thedownhole gauge 500 employs itssecond sensor 260 for measuring the pressure and/or temperature of a remote zone, and uses the third sensor 280 (e.g., now in a sixthgauge housing section 510 a) for measuring the annulus pressure. - Additionally, the
downhole gauge 500 may include aninternal wire passageway 550, such that a wire (e.g., TEC) may traverse the length of thedownhole gauge 500. Thus, rather than thedownhole gauge 500 having thehydraulic line 230 andhydraulic line connection 235, thedownhole gauge 500 may include asecond TEC 520 and associatedsecond TEC connection 525. - Turning to
FIGS. 6A through 6E , illustrated are different views of an alternative embodiment of adownhole gauge 600 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 600 ofFIGS. 6A through 6E is similar in many respects to thedownhole gauge 500 ofFIGS. 5A through 5E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features. Thedownhole gauge 600 differs, for the most part, from thedownhole gauge 500, in that thedownhole gauge 600 employssimple holes 610 in the gauge housing 210 (e.g., holes extending through the sidewall thickness of thegauge housing 210 in either of the fifthgauge housing section 210 e or sixthgauge housing section 510 a) to provide access to fluid within the annulus. In contrast, thedownhole gauge 500 employs a sensor manifold housing for its fifthgauge housing section 210 e. - Turning to
FIGS. 7A through 7E , illustrated are different views of an alternative embodiment of adownhole gauge 700 designed, manufactured and/or operated according to one or more embodiments of the disclosure. Thedownhole gauge 700 ofFIGS. 7A through 7E is similar in many respects to thedownhole gauge 500 ofFIGS. 5A through 5E . Accordingly, like reference numbers have been used to indicate similar, if not identical, features. Thedownhole gauge 700 differs, for the most part, from thedownhole gauge 500, in that thedownhole gauge 700 employs afourth sensor 740. Thefourth sensor 740, as discussed above, may be any type of sensor and remain within the scope of the disclosure. For instance, thefourth sensor 740 could be another pressure and/or temperature sensor that is configured to measure the pressure and/or temperature of another location, or alternatively could be a redundant pressure and/or temperature sensor configured to measure the pressure and/or temperature of an existing location. Alternatively, thefourth sensor 740 could be a different type of sensor other than a pressure and/or temperature sensor. Moreover, whileFIGS. 7A through 7E show thefourth sensor 740 positioned to the left of thefirst sensor 240, thefourth sensor 740 could be located at any other position within thegauge housing 210 and remain within the scope of the disclosure. - A downhole gauge according to the present disclosure has many benefits. For example, a downhole gauge with three or more sensors (e.g., three or more pressure and/or temperature sensors) minimizes TEC terminations, minimizes downhole gauge length (e.g., vs adding downhole gauge below) and minimizes potential leak paths. A downhole gauge with three or more sensors (e.g., three or more pressure and/or temperature sensors) also minimizes downhole gauge “footprint” on the gauge mandrel, reduces gauge mandrel OD, and enables installation of downhole gauge in tight casing scenarios. Similarly, the downhole gauge with hydraulic connection at the bottom eliminates the need to machine hydraulic channels in the gauge mandrel to enable the downhole gauge to monitor a remote zone, reduces gauge mandrel complexity, and minimizes gauge mandrel OD. Furthermore, a downhole gauge with three or more sensors (e.g., three or more pressure and/or temperature sensors) provides additional monitoring capabilities, reduced complexity (e.g., vs installing separate tool(s)) and reduces potential leak paths. Likewise, a downhole gauge with three pressure and/or temperature sensors, and the option to add additional sensors, along with a TEC feedthrough, enables multi-drop capability.
- Aspects disclosed herein include:
- A. A downhole gauge for use in a wellbore, the downhole gauge including: 1) a gauge housing, the gauge housing having a first end and a second opposing end; and 2) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
- B. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; 2) a tubular located within the wellbore; and 3) a downhole gauge coupled with the tubular within the wellbore, the downhole gauge including: a) a gauge housing, the gauge housing having a first end and a second opposing end; and b) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
- C. A method, the method including: 1) positioning a tubular within a wellbore extending through one or more subterranean formations, the tubular having a downhole gauge coupled therewith, the downhole gauge including: a) a gauge housing, the gauge housing having a first end and a second opposing end; and b) first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end; and 2) measuring one or more properties within the wellbore using the first, second and third sensors located within the interior of the gauge housing.
- Aspects A, B, and C may have one or more of the following additional elements in combination: Element 1: further including a tubing encapsulated conductor (TEC) coupled to the first end of the gauge housing using a tubing encapsulated conductor (TEC) connection. Element 2: wherein the tubing encapsulated conductor (TEC) is a first tubing encapsulated conductor (TEC), and further including a second tubing encapsulated conductor (TEC) coupled to the second end of the gauge housing using a second tubing encapsulated conductor (TEC) connection. Element 3: further including one or more internal wire passageways extending from the first and second opposing ends of the gauge housing, the one or more internal wire passageways configured to couple the first tubing encapsulated conductor (TEC) and the second tubing encapsulated conductor (TEC). Element 4: wherein the gauge housing includes a plurality of interconnected gauge housing sections. Element 5: wherein the first sensor is a first pressure and/or temperature sensor, the first pressure and/or temperature sensor configured to measure a first pressure and/or temperature in an inside diameter (ID) of tubing that the downhole gauge is coupled. Element 6: wherein the second sensor is a second pressure and/or temperature sensor, the second pressure and/or temperature sensor configured to measure a second pressure and/or temperature in an annulus surrounding the tubing that the downhole gauge is coupled. Element 7: wherein the third sensor is a third pressure and/or temperature sensor, the third pressure and/or temperature sensor configured to measure a third pressure and/or temperature of a remote zone. Element 8: further including a fourth sensor located within the interior the gauge housing, the fourth sensor not configured to measure pressure and/or temperature. Element 9: wherein one or more of the first, second and third sensors is a sensor set, each sensor set including communication electronics and sensor electronics on a single board. Element 10: wherein the downhole gauge is a first downhole gauge, and further including a second downhole gauge coupled with the tubular within the wellbore, the first and second downhole gauges forming a sensor array, the second downhole gauge including: i) a second gauge housing, the second gauge housing having opposing ends; and ii) a second set of first, second and third sensors located within an interior of the second gauge housing between the opposing ends.
- Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.
Claims (22)
1. A downhole gauge for use in a wellbore, comprising:
a gauge housing, the gauge housing having a first end and a second opposing end; and
first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
2. The downhole gauge as recited in claim 1 , further including a tubing encapsulated conductor (TEC) coupled to the first end of the gauge housing using a tubing encapsulated conductor (TEC) connection.
3. The downhole gauge as recited in claim 2 , wherein the tubing encapsulated conductor (TEC) is a first tubing encapsulated conductor (TEC), and further including a second tubing encapsulated conductor (TEC) coupled to the second end of the gauge housing using a second tubing encapsulated conductor (TEC) connection.
4. The downhole gauge as recited in claim 3 , further including one or more internal wire passageways extending from the first and second opposing ends of the gauge housing, the one or more internal wire passageways configured to couple the first tubing encapsulated conductor (TEC) and the second tubing encapsulated conductor (TEC).
5. The downhole gauge as recited in claim 1 , wherein the gauge housing includes a plurality of interconnected gauge housing sections.
6. The downhole gauge as recited in claim 1 , wherein the first sensor is a first pressure and/or temperature sensor, the first pressure and/or temperature sensor configured to measure a first pressure and/or temperature in an inside diameter (ID) of tubing that the downhole gauge is coupled.
7. The downhole gauge as recited in claim 6 , wherein the second sensor is a second pressure and/or temperature sensor, the second pressure and/or temperature sensor configured to measure a second pressure and/or temperature in an annulus surrounding the tubing that the downhole gauge is coupled.
8. The downhole gauge as recited in claim 7 , wherein the third sensor is a third pressure and/or temperature sensor, the third pressure and/or temperature sensor configured to measure a third pressure and/or temperature of a remote zone.
9. The downhole gauge as recited in claim 8 , further including a fourth sensor located within the interior the gauge housing, the fourth sensor not configured to measure pressure and/or temperature.
10. The downhole gauge as recited in claim 1 , wherein one or more of the first, second and third sensors is a sensor set, each sensor set including communication electronics and sensor electronics on a single board.
11. A well system, comprising:
a wellbore extending through one or more subterranean formations;
a tubular located within the wellbore; and
a downhole gauge coupled with the tubular within the wellbore, the downhole gauge including:
a gauge housing, the gauge housing having a first end and a second opposing end; and
first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end.
12. The well system as recited in claim 11 , further including a tubing encapsulated conductor (TEC) coupled to the first end of the gauge housing using a tubing encapsulated conductor (TEC) connection.
13. The well system as recited in claim 12 , wherein the tubing encapsulated conductor (TEC) is a first tubing encapsulated conductor (TEC), and further including a second tubing encapsulated conductor (TEC) coupled to the second end of the gauge housing using a second tubing encapsulated conductor (TEC) connection.
14. The well system as recited in claim 13 , further including one or more internal wire passageways extending from the first and second opposing ends of the gauge housing, the one or more internal wire passageways configured to couple the first tubing encapsulated conductor (TEC) and the second tubing encapsulated conductor (TEC).
15. The well system as recited in claim 11 , wherein the gauge housing includes a plurality of interconnected gauge housing sections.
16. The well system as recited in claim 11 , wherein the first sensor is a first pressure and/or temperature sensor, the first pressure and/or temperature sensor configured to measure a first pressure and/or temperature in an inside diameter (ID) of tubing that the downhole gauge is coupled.
17. The well system as recited in claim 16 , wherein the second sensor is a second pressure and/or temperature sensor, the second pressure and/or temperature sensor configured to measure a second pressure and/or temperature in an annulus surrounding the tubing that the downhole gauge is coupled.
18. The well system as recited in claim 17 , wherein the third sensor is a third pressure and/or temperature sensor, the third pressure and/or temperature sensor configured to measure a third pressure and/or temperature of a remote zone.
19. The well system as recited in claim 18 , further including a fourth sensor located within the interior the gauge housing, the fourth sensor not configured to measure pressure and/or temperature.
20. The well system as recited in claim 11 , wherein one or more of the first, second and third sensors is a sensor set, each sensor set including communication electronics and sensor electronics on a single board.
21. The well system as recited in claim 11 , wherein the downhole gauge is a first downhole gauge, and further including a second downhole gauge coupled with the tubular within the wellbore, the first and second downhole gauges forming a sensor array, the second downhole gauge including:
a second gauge housing, the second gauge housing having opposing ends; and
a second set of first, second and third sensors located within an interior of the second gauge housing between the opposing ends.
22. A method, comprising:
positioning a tubular within a wellbore extending through one or more subterranean formations, the tubular having a downhole gauge coupled therewith, the downhole gauge including:
a gauge housing, the gauge housing having a first end and a second opposing end; and
first, second and third sensors located within an interior of the gauge housing between the first end and the second opposing end; and
measuring one or more properties within the wellbore using the first, second and third sensors located within the interior of the gauge housing.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US18/508,813 US20240159143A1 (en) | 2022-11-15 | 2023-11-14 | Multi-sensor downhole gauge |
PCT/US2023/079745 WO2024107796A1 (en) | 2022-11-15 | 2023-11-15 | Multi-sensor downhole gauge |
Applications Claiming Priority (2)
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US202263425349P | 2022-11-15 | 2022-11-15 | |
US18/508,813 US20240159143A1 (en) | 2022-11-15 | 2023-11-14 | Multi-sensor downhole gauge |
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US20240159143A1 true US20240159143A1 (en) | 2024-05-16 |
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US18/508,813 Pending US20240159143A1 (en) | 2022-11-15 | 2023-11-14 | Multi-sensor downhole gauge |
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WO2016196425A1 (en) * | 2015-06-01 | 2016-12-08 | Gas Sensing Technology Corp. | Suspended fluid sampling & monitoring |
AU2016405318B2 (en) * | 2016-04-28 | 2021-09-23 | Halliburton Energy Services, Inc. | Distributed sensor systems and methods |
GB201902732D0 (en) * | 2019-02-28 | 2019-04-17 | Expro North Sea Ltd | Pressure seal with built in testing system |
US20220136337A1 (en) * | 2020-11-05 | 2022-05-05 | Halliburton Energy Services, Inc. | Downhole electrical conductor movement arrestor |
US20220220818A1 (en) * | 2021-01-14 | 2022-07-14 | Halliburton Energy Services, Inc. | Gauge sensor for downhole pressure/temperature monitoring of esp intake pressure and discharge temperature |
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