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Title: Downhole Power Generation and Wireless Communications for Intelligent Completions Applications

Abstract

Tubel Tech has been working with the DoE Rocky Mountain test center to create a CRADA which will allow Tubel Tech to test its wireless gauge in a well at the test center. The CRADA agreement should be completed by the next quarter and Tubel Tech expects to perform the final test on this project during the next quarter as well. The wireless gauge has not been modified or upgraded during this report period.

Authors:
Publication Date:
Research Org.:
Tubel Technologies, Inc.
Sponsoring Org.:
USDOE
OSTI Identifier:
859938
DOE Contract Number:
FC26-02NT41601
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
02 PETROLEUM; 42 ENGINEERING; ON-SITE POWER GENERATION; WELL COMPLETION; DATA TRANSMISSION SYSTEMS; MEASURING INSTRUMENTS

Citation Formats

Paul Tubel. Downhole Power Generation and Wireless Communications for Intelligent Completions Applications. United States: N. p., 2005. Web. doi:10.2172/859938.
Paul Tubel. Downhole Power Generation and Wireless Communications for Intelligent Completions Applications. United States. doi:10.2172/859938.
Paul Tubel. Mon . "Downhole Power Generation and Wireless Communications for Intelligent Completions Applications". United States. doi:10.2172/859938. https://www.osti.gov/servlets/purl/859938.
@article{osti_859938,
title = {Downhole Power Generation and Wireless Communications for Intelligent Completions Applications},
author = {Paul Tubel},
abstractNote = {Tubel Tech has been working with the DoE Rocky Mountain test center to create a CRADA which will allow Tubel Tech to test its wireless gauge in a well at the test center. The CRADA agreement should be completed by the next quarter and Tubel Tech expects to perform the final test on this project during the next quarter as well. The wireless gauge has not been modified or upgraded during this report period.},
doi = {10.2172/859938},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon Nov 07 00:00:00 EST 2005},
month = {Mon Nov 07 00:00:00 EST 2005}
}

Technical Report:

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  • The first quarter of the Downhole Power Generation and Wireless Communications for Intelligent Completions Applications was characterized by the evaluation and determination of the specifications required for the development of the system for permanent applications in wellbores to the optimization of hydrocarbon production. The system will monitor and transmit in real time pressure and temperature information from downhole using the production tubing as the medium for the transmission of the acoustic waves carrying digital information. The most common casing and tubing sizes were determined by interfacing with the major oil companies to obtain information related to their wells. The conceptualmore » design was created for both the wireless gauge section of the tool as well as the power generation module. All hardware for the wireless gauge will be placed in an atmospheric pressure chamber located on the outside of a production tubing with 11.4 centimeter (4-1/2 inch) diameter. This mounting technique will reduce cost as well as the diameter and length of the tool and increase the reliability of the system. The power generator will use piezoelectric wafers to generate electricity based on the flow of hydrocarbons through an area in the wellbore where the tool will be deployed. The goal of the project is to create 1 Watt of power continuously.« less
  • The third quarter of the project was dedicated to creating the detailed design for the manufacturing of the mechanical system for wireless communications and the power generation module. Another emphasis for the quarter was the development of the surface system and acoustic detector for the downhole tool for 2 way communications. The tasks accomplished during this report period were: (1) All detailed drawings for manufacturing of the wireless communications gauge and power generator were completed and the drawings were forward to a machine shop for manufacturing. (2) The power generator was incorporated to the mandrel of the wireless gauge reducingmore » the length of the tool by 25% and manufacturing cost by about 35%. (3) The new piezoelectric acoustic generator was manufactured successfully and it was delivered during this quarter. The assembly provides a new technique to manufacture large diameter piezoelectric based acoustic generators. (4) The acoustic two-way communications development progressed significantly. The real time firmware for the surface system was developed and the processor was able to detect and process the data frame transmitted from downhole. The analog section of the tool was also developed and it is being tested for filtering capabilities and signal detection and amplification. (5) The new transformer to drive the piezoelectric wafer assembly was designed and manufactured. The transformer has been received and it will go through testing and evaluation during the next quarter.« less
  • The fourth quarter of the project was dedicated to the manufacturing of the mechanical system for wireless communications and the power generation module and inspection pre assembly of the mechanical components. Another emphasis for the quarter was the development of filter control and signal detection software. The tasks accomplished during this report period were: (1) Dimensional issues were resolved and revised drawings for manufacturing of the wireless communications gauge and power generator were completed and sent to a machine shop for manufacturing. (2) Finalized the requirements and fittings and connections for testing the tool in the Halliburton flow loop. (3)more » The new acoustic generator was manufactured successfully and it was delivered during this quarter. The assembly will be outsourced for plastic coating in preparation for hostile environment use. (4) The acoustic two-way communications development continued to progress. The real time firmware for the surface system was developed and the processor was able to detect and process the data frame transmitted from downhole. The analog section of the tool was also developed and it is being tested for filtering capabilities and signal detection and amplification. (5) The new transformer to drive the acoustic generator assembly was manufactured and was successfully tested. Spring mandrel design showed increased acoustic output on the pipe and was implemented. (6) PCBA board carrier with board set was tested for function and fit and is 100% complete. (7) Filter control software is complete and software to allow modification of communication parameters dynamically is 50% complete. (8) All mechanical parts to assemble the wireless gauge and power generator have been received and verified to be within specification. (9) Acoustic generator has been assembled in the tool mandrel and tested successfully. (10) The circuit required to harvest the power generated downhole has been designed and the power generator components have been received.« less
  • The development work during this quarter was focused in the assembly of the downhole power generator hardware and its electronics module. The quarter was also spent in the development of the surface system electronics and software to extract the acoustic data transmitted from downhole to the surface from the noise generated by hydrocarbon flow in wells and to amplify very small acoustic signals to increase the distance between the downhole tool and the surface receiver. The tasks accomplished during this report period were: (1) Assembly of the downhole power generator mandrel for generation of electrical power due to flow inmore » the wellbore. (2) Test the piezoelectric wafers to assure that they are performing properly prior to integrating them to the mechanical power generator mandrel. (3) Coat the power generator wafers to prevent water from shorting the power generator wafers. (4) Test of the power generator using a water tower and an electric pump to create a water flow loop. (5) Test the power harvesting electronics module. (6) Upgrade the signal condition and amplification from downhole into the surface system. (7) Upgrade the surface processing system capability to process data faster. (8) Create a new filtering technique to extract the signal from noise after the data from downhole is received at the surface system.« less
  • The wireless gauge has not been modified or upgraded during this report period. Tubel Tech is working with the DoE Rocky Mountain test center to create a CRADA to allow Tubel Tech to test its tool in a well at the test center.