Downhole distributed pressure sensor arrays, downhole pressure sensors, downhole distributed pressure sensor arrays including quartz resonator sensors, and related methods

• US 10,132,156 B2
• Filed: 10/27/2015
• Issued: 11/20/2018
• Est. Priority Date: 11/03/2014
• Status: Active Grant

• Current Assignee: ChampionX LLC (ChampionX Corporation)
• Original Assignee: Quartzdyne, Inc. (ChampionX Corporation)
• Inventors: Leeflang, Brian T., Brown, G. Scott
• Primary Examiner(s): Gibson, Randy
• Assistant Examiner(s): Kidanu, Gedeon M
• Application Number:
  US14/923,943
• Publication Number:
  US 20160123133A1
• Time in Patent Office: 1,120 Days
• CPC Class Codes: E21B 47/01 Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: G01L 11/04 by acoustic means
• CPC Class Codes: G01L 9/085 with temperature compensating means non electric temperature compensating means G01L19/04
• CPC Class Codes: H03H 9/19 consisting of quartz

Abstract

Downhole distributed pressure sensor arrays include sensor housings each comprising at least one pressure sensor in a pressure housing. Downhole pressure sensors include a housing, at least one pressure sensor in a pressure housing portion of the housing, and at least one isolation element positioned at an outer wall of the housing.

Claims

1. A downhole distributed pressure sensor array, comprising:

sensor housings each having a longitudinal axis, at least one sensor housing of the sensor housings comprising at least one pressure sensor disposed in a sealed pressure housing for detecting a pressure of an environment external to the at least one sensor housing, the at least one sensor housing having an opening defined in a lateral sidewall of the at least one sensor housing extending along the longitudinal axis of the at least one sensor housing, the opening configured to place the at least one pressure sensor in communication with the pressure of the environment external to the at least one sensor housing via a fluid;

cable segments connecting the sensor housings; and

at least one electrical conductor extending along the longitudinal axes of the sensor housings and through at least one cable segment of the cable segments and connecting the at least one sensor housing to an adjacent sensor housing of the sensor housings, wherein a portion of the at least one electrical conductor passes within the at least one sensor housing around, spaced from, and exterior to an entirety of the sealed pressure housing of the at least one sensor housing.

2. The downhole distributed pressure sensor array of claim 1, further comprising weld joints, each weld joint of the weld joints bonding a respective sensor housing of the sensor housings to a jacket of a respective cable segment of the cable segments, a conductor of the respective cable segment and the jacket being separated by a void proximate the weld joint, the void extending from the at least one electrical conductor to the respective cable segment.

3. The downhole distributed pressure sensor array of claim 1, wherein the at least one sensor housing further comprises at least one chamber in the pressure housing holding the at least one pressure sensor, and wherein the pressure housing comprises an enlarged wall portion positioned on a first lateral side of the at least one chamber in the pressure housing and a normal wall portion on a second lateral side of the at least one chamber in the pressure housing opposing the first lateral side, a width of the enlarged wall portion taken in a direction transverse to the longitudinal axis of the at least one sensor housing being greater than a width of the normal wall portion taken in the direction transverse to the longitudinal axis of the at least one sensor housing, wherein the at least one electrical conductor extends through an aperture in the enlarged wall portion.

4. The downhole distributed pressure sensor array of claim 1, wherein the at least one electrical conductor comprises electrical conductors, wherein the at least one sensor housing further comprises an electronics assembly, and wherein the at least one electrical conductor is electronically coupled to the electronics assembly and extends from a first electrical conductor of the electrical conductors at a first end of the at least one sensor housing through the pressure housing and past the at least one pressure sensor to a second electrical conductor of the electrical conductors at a second end of the at least one sensor housing opposing the first end.

5. The downhole distributed pressure sensor array of claim 1, wherein the at least one sensor housing further comprises at least one chamber in the pressure housing in communication with the at least one pressure sensor, the at least one chamber in communication with at least one portion of the sidewall of the at least one sensor housing and containing the fluid comprising a substantially incompressible fluid.

6. The downhole distributed pressure sensor array of claim 5, wherein the at least one sensor housing further comprises at least one diaphragm coupled to the at least one sensor housing at the sidewall of the at least one sensor housing in communication with the at least one chamber, the at least one diaphragm defining a portion of the sidewall of the at least one sensor housing.

7. The downhole distributed pressure sensor array of claim 1, wherein the at least one sensor housing further comprises a feedthrough portion comprising at least one aperture in a portion of the at least one sensor housing extending along the longitudinal axis of the at least one sensor housing and along the pressure housing.

8. The downhole distributed pressure sensor array of claim 7, wherein the at least one sensor housing further comprises an electronics assembly disposed in an electronics housing portion, and wherein the at least one electrical conductor is electronically coupled to the electronics assembly and extends through the at least one aperture of the feedthrough portion, past the at least one pressure sensor, and to the electronics assembly.

9. The downhole distributed pressure sensor array of claim 1, wherein the at least one sensor housing further comprises at least one chamber in the pressure housing holding the at least one pressure sensor, and wherein a longitudinal axis of the at least one chamber in the pressure housing holding the at least one pressure sensor is laterally offset from the longitudinal axis of the at least one sensor housing in a direction transverse to the longitudinal axis of the at least one sensor housing.

10. The downhole distributed pressure sensor array of claim 9, wherein a lateral cross section of the at least one chamber in the pressure housing taken in a direction transverse to the longitudinal axis intersects only one chamber, and wherein each of the at least one sensor housing and the one chamber in the pressure housing comprises a substantially elliptical or circular shape, and wherein a centerline of the at least one sensor housing is laterally offset from a centerline of the one chamber in the pressure housing.

11. A downhole distributed pressure sensor array, comprising:

sensor housings, each sensor housing having a longitudinal axis and comprising;

at least one pressure sensor;

at least one chamber in the sensor housing holding a substantially incompressible fluid and in communication with the at least one pressure sensor, the at least one chamber in communication with a sidewall of the sensor housing in a direction transverse to the longitudinal axis of the sensor housing; and

at least one diaphragm coupled to the sensor housing in communication with the at least one chamber and positioned at and defining a portion of the sidewall of the sensor housing, the at least one chamber and the at least one diaphragm defining a sealed volume in the sensor housing; and

electrical conductors extending through cable segments between adjacent sensor housings and connecting each sensor housing of the sensor housings to an adjacent sensor housing, wherein a portion of at least one of the electrical conductors passes within the sensor housing around, spaced from, and exterior to an entirety of the sealed volume in the sensor housing.

12. The downhole distributed pressure sensor array of claim 11, wherein a portion of each of the electrical conductors passes within a respective sensor housing and entirely around the at least one chamber in the sensor housing.

13. The downhole distributed pressure sensor array of claim 11, wherein at least one sensor housing of the sensor housings further comprises a feedthrough portion comprising at least one aperture in a portion of the at least one sensor housing extending along the longitudinal axis of the at least one sensor housing and along the at least one chamber in the at least one sensor housing, a portion of at least one electrical conductor of the electrical conductors passing through the at least one aperture of the feedthrough portion.

14. The downhole distributed pressure sensor array of claim 13, wherein a lateral cross section of the at least one chamber in the pressure housing taken in a direction transverse to the longitudinal axis of the sensor housing intersects only one chamber, and wherein a longitudinal axis of the one chamber in the at least one sensor housing is laterally offset from the longitudinal axis of the at least one sensor housing in a direction transverse to the longitudinal axis of the at least one sensor housing.

15. A downhole pressure sensor, comprising:

at least one pressure sensor; and

a housing having a longitudinal axis, the housing comprising;

at least one chamber in a pressure housing portion of the housing holding the at least one pressure sensor and holding a substantially incompressible fluid, the at least one chamber extending through at least one portion of an outer wall of the housing; and

isolation elements coupled to the pressure housing portion of the housing, at least two of the isolation elements each being in communication with a single common chamber of the at least one chamber and positioned at the outer wall of the housing.

16. The downhole pressure sensor of claim 15, further comprising an electronics assembly, wherein the housing further comprises:

an electronics housing portion having the electronics assembly disposed therein; and

a feedthrough portion comprising at least one aperture extending through the pressure housing portion of the housing along the longitudinal axis; and

at least one electrical conductor electronically coupled to the electronics assembly, the at least one electrical conductor extending through the at least one aperture of the feedthrough portion to the electronics assembly.

17. The downhole pressure sensor of claim 16, wherein the feedthrough portion of the housing extends through a thick wall portion of the pressure housing portion of the housing having a lateral width taken in a direction transverse to the longitudinal axis of the housing that is greater than a lateral width taken in a direction transverse to the longitudinal axis of the housing of another wall portion of the pressure housing portion of the housing.

18. A downhole distributed pressure sensor array, comprising:

sensor housings, each sensor housing comprising at least one quartz resonator pressure sensor disposed in a pressure housing for detecting a pressure of an environment external to the sensor housing;

cable segments connecting the sensor housings; and

electrical conductors extending through the cable segments and connecting each sensor housing of the sensor housings to an adjacent sensor housing, wherein a portion of each of the electrical conductors passes within a respective sensor housing and around, spaced from, and exterior to the pressure housing in the sensor housing.

19. The downhole distributed pressure sensor array of claim 18, wherein a portion of the electrical conductors pass within at least one sensor housing of the sensor housings around an entirety of the pressure housing of the at least one sensor housing.

20. The downhole distributed pressure sensor array of claim 18, wherein the at least one quartz resonator pressure sensor exhibits a lateral outer dimension of less than about 0.575 inch (14.605 millimeters).