Miniature pump-through sensor modules

• US 6,324,904 B1
• Filed: 08/18/2000
• Issued: 12/04/2001
• Est. Priority Date: 08/19/1999
• Status: Expired due to Fees

• Current Assignee: Ball Semiconductor, Inc.
• Original Assignee: Ball Semiconductor, Inc.
• Inventors: Ishikawa, Akira, Ahn, Suzanne I., Takeda, Nabuo, Hays, Steven R.
• Primary Examiner(s): Larkin, Daniel S.
• Assistant Examiner(s): Politzer, Jay L.
• Application Number:
  US09/641,480
• Time in Patent Office: 473 Days
• Field of Search: 731/52
• US Class Current: 73/152.03
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/138 Devices entrained in the flow of well-bore fluid for transmitting data, control or actuation signals
• CPC Class Codes: E21B 47/26 Storing data down-hole, e.g. in a memory or on a record carrier
• CPC Class Codes: H01L 29/0657 characterised by the shape of the body
• CPC Class Codes: H01L 2924/1017 being a sphere

Abstract

Sensor modules are provided which are pumped into a well by first being pumped downhole within a drill string, then passing through the drill bit and being circulated uphole in the annulus between the drill string and the borehole of the well. The sensors take measurement readings as they are being pumped uphole through the annulus. The sensors are preferably separated from the mud returns from the well, and then read at an inductive read unit. The sensor modules are provided by semiconductor substrates which measure downhole well parameters, and then store the date for retrieval at the surface. The semiconductor substrates preferably have a plurality of sides on which measurement sensors and circuitry may be formed, allowing the circuitry and the sensors to be made of smaller sizes. Such sensors include temperature sensors, three-dimensional stain gauges, which are also useful as pressure transducers, inductive pressure transducers, inclination sensors, accelerometers, gyroscopes and radiation detectors. The sensors and circuitry are preferably provided on spherically shaped semiconductor substrates.

Claims

1. A method for sensing downhole measurement parameters in a well, comprising the steps of:

providing a plurality of sensor modules, each having a sensor section, a storage register and a power source which are encapsulated in a protective outer covering, and operative for sensing at least one desired parameter and storing a value therefor in a storage register;

injecting the plurality of the sensors modules into a flow line connected to the drill string;

pumping the sensor modules downhole, through a lower portion of the drill string and into an annulus defined between the drill string and a borehole of the well,

detecting the desired parameter and storing the value therefor in the storage register; and

passing the sensor modules to a read unit to read the value of the parameter stored in the storage register.

2. The method of claim 1, further comprising the step of providing a plurality of the sensor modules of various types for measuring respective ones of different parameters.

3. The method of claim 1, further comprising the step of exposing the sensor modules to an electromagnetic field disposed in a selected location, to activate the sensor modules to store the value for the selected parameter.

4. The method of claim 3, wherein exposing the sensor module to the electromagnetic field provides operative power to the sensor modules.

5. The method of claim 4, wherein operative power is only applied to the sensor module when disposed within the electromagnetic field.

6. The method of claim 5, wherein at least a portion of the plurality of the sensor modules only record one value for the parameter, and the respective value is stored in the respective storage register when operative power is removed from the sensor modules.

7. The method of claim 1, wherein the step of providing the sensor modules comprises forming each of the sensor section, the storage register and the power source on a single spherically shaped semiconductor substrate.

8. The method of claim 1, wherein the step of passing the sensor modules to a read unit and reading the value of the parameter stored in the storage register comprises emitting an electromagnetic control signal from the read unit to the sensor module, which, in response to the electromagnetic control signal, emits an electromagnetic data signal with the value of the parameter encoded on the electromagnetic data signal.

9. The method of claim 8, wherein the plurality of sensor modules includes sensor modules of various types for measuring different types of parameters and recording values therefor, and said sensor modules are responsive to respective ones of different electromagnetic control signals to emit respective electromagnetic data signals at the read unit.