UPM 17010 Highly Accurate Pressure and Differential … · 23-02-2017 · tests included: MEMS die only (on T08 header, Figure 3); MEMS die installed into packaging (with no oil);

Copyright 2017, Letton Hall Group. This paper was developed for the UPM Forum, 22 – 23 February 2017, Houston, Texas, U.S.A., and is subject to correction by the author(s). The contents of the paper may not necessarily reflect the views of the UPM Forum sponsors or administrator. Reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Letton Hall Group is prohibited. Non-commercial reproduction or distribution may be permitted, provided conspicuous acknowledgment of the UPM Forum and the author(s) is made. For more information, see www.upmforum.com.

AbstractUsing funds provided by the Research Partnership toSecureEnergyforAmerica(RPSEA),theLettonHallGroup,Innoveeringanditsteampartnershavedevelopedahigh-pressure, high-temperature (HPHT) sensor suite thatincludesanabsolutepressure(P)sensorandadifferentialpressure (DP) sensor for use in ultra-deepwatermeasurement applications (multiphase and wet gasflowmeters)aswellassubseaanddownholeapplications.Anovel,highpressure(15,000psia),hightemperature(250°C), high accuracy differential pressure sensor wasdesigned,fabricatedandtestedbyourteam.Theteamalsodeveloped and fabricated a specially-designedelectromechanicalsilicon(MEMS)bridgecircuittoprovidetheHPHTdifferentialpressure-sensingelement. Thiswasincorporated intoapressurecell foreventual integrationintohigh-pressureflowmeterhousings.AfterintenseR&Dand continued technology developmentwe are ready topresent preliminary results of its experimental andmetrology testing. Some applications for this HPHTpressuresensorsuitewillalsobebrieflydiscussed.

IntroductionIn the past decade, Oil and Gas (O&G) exploration andoperations have never been more abundant throughouttheworldwithfarreachingimplicationstopeoples’ lives.Low fuel prices are fueling the trend in total worldwidedemandforoilincreasing.WiththeemergenceoftheAsiaPacificeconomiesandtheiremergingmarkets,theneedforaffordable and abundant energy has permeated mostindustrial economies. Presently, the low price of oil is achallenge, proceeding through a cycle that has beenexperiencedinthepast.

During this downturn, oil and gas exploration companiesare focusing on cost effective production, which meansintroducing new technologies to help reduce productioncostswhile improvingtheefficiency,reliabilityandsafetyof existing processes. Thesenew technologies span frombetter pumps and rigs to smart wellheads with highpressure high temperature (HPHT) components,particularlysensors.

This paper will focus on the technology development,conductedbytheauthorsoverthepast4.5years,ofHPHTabsolute and differential pressure sensors for upstreamanddownholeapplications.Wewill present someofourpreliminarydata,aswellassuggestedapplicationsforthisnewsuiteofHPHTpressuresensors.

BackgroundAsunconventionaldrillingoperationsincreasethroughoutthe world, there is a need for subsea and downholeequipment and their instrumentation, to withstand thehighpressures(upto20,000psia)andhightemperatures(up to 200°C or more), [1]. This combination of highpressuresandtemperaturesposesignificantchallengestoequipment materials, packaging, performance andreliability.IntheO&Gindustrythereisaneedtoaccuratelymeasurethe flow rates of well fluids, either in upstreamMulti-Phase Flow Meters (MPFMs), subsea equipment or indownholeapplications(egmudflow).CurrentDPsensormeasurements,fordownholeapplications,aremadewithtwoabsolutepressuretransmitters,whichdonotprovidetherequiredaccuracyattheseHPHTconditions,andalsodonotprovideatruedifferentialpressuremeasurement.Inaddition,aroundtheglobetherearenumerousoilandgaswells being drilled, each facing different challenges,withonecommonality:theyallhavethepotentialforwellcontrolincidentswhichcanresultinlossofcrew/riganddamagetotheenvironment.Therearenumerousindustryand academic entities performing research in kickdetection systems/algorithms, [2-4], but no downholemuddensitysensors,toourteam’sknowledge,currentlyexists.Theaboveapplicationsshareacommonneedforhighlyaccurate pressure and differential pressure sensormeasurements in the HPHT downhole environment. Toaddressthisneed,theLettonHallGroupandInnoveeringteam have been working together on the technologydevelopment of HPHT sensors, both absolute anddifferential sensors, for both upstream/subsea anddownhole applications. This technology development

UPM17010

HighlyAccuratePressureandDifferentialPressureSensorsforHPHTEnvironmentsNicholasTiliakos,Innoveering;JimHall,LettonHallGroup;TimWorst,Measurements,Ltd;RonFoster,LettonHallGroup;JoeBrown,LettonHallGroup


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effort,fundedbyRPSEA/DOEunderthe07121-1301and-4304 programs, has led to the design, fabrication andtestingof:sixdifferentialpressuresensors(twoofwhichare for mud density change/kick detection, calledMDSsensors)andtwoabsolutepressuresensors,packagedfordownholeapplications.Thiscomprisesourteams’HPHTP,DP,MDSsensorsuite,Figure1,[5-7].Thissensorsuiteleverages2ndGenerationMEMSSilicon-on-Insulator(SOI)chiptechnologyfirstusedaspartofatirepressuremonitoringsensorforNASA’sSpaceShuttle,(GEN1) developed by Dr. Jim Hall, [8]. This secondgeneration (GEN2) MEMS die technology utilizes apiezoresistorWheatstonebridgefabricated,usingMEMSmicrofabricationmethods,ontoanSOIwafertoinsulateand prevent leakage currents from disrupting the chiptransduction at high temperatures (>120°C). The piezo-resistors are embedded onto the MEMS’s diaphragm,whereupondeflection,transmitsamVlevelvoltagesignalproportionaltothisdifferentialpressureforce.

P-DP-MDSSensorDesign/FabricationOverviewMost of the design details regarding the sensor’s over-pressure protection capability, metallization, and oil fillvolumewerediscussed inpreviouspapersby theauthors,[5-7].TheP-DPsensorsourteamdesigned,Figure1,hadtoadheretothefollowingtopleveldesignrequirements:

1. OverallDPsensorOD≤1.0“fordownholeunits;2. Survive up to 15,000 psia with 1.5x pressure

(22,500psia);3. Operatingtemperaturerangeof-10°Cto250°C;4. Maintaingood linearityandminimalsensitivity to

temperature and CMP (CommonMode Pressure)effects.

5. Mustwithstandcorrosiveenvironment;6. DPrange:0-75psid

FortheMDSsensorapplication,requirements1-5holdaswellasthefollowing:7. 3footseparationbetweenremoteseals;8. Maximumabsolutepressure=20,000psia;9. MaximumremotesealOD≤1.5”.10. DPrange:0-15psid;11. Measureminimum change inmud density of 0.1

ppg.

Theaboverequirementsdrovethesensordesignsfromtheoriginal2.05”OD,Figure1a,to1.0”Figure1b-c.Ourinitialsensordesign includedbothanabsoluteandadifferentialMEMS die, Figure 1a, thereby providing both P-DPmeasurementsinasensorpackagethatwas2.05”ODx2.1”length(w/oendfittings).

Based on the above requirements the sensors weredesignedwith the samematerials,mainly Inconel 625 forthepackaging,HastelloyC276fortheisolationdiaphragms.All assembly processes were carefully implemented andmonitored. Innoveering’s Metrology Station, Figure 2a-b,utilizesanon-contactlasersystem,with2µmresolution.Itwas used to ensure: (i) isolation diaphragm corrugatedfeatures were not compromised after welding, Figure 2b;and (ii) parts were within the required specifications andtolerances. Likewise, all welding processes were carefullymonitoredwithappropriateweldpenetrationdepthsaswellas monitoring of internal sensor temperatures, duringwelding,toensurelocalizedheatingdidnotexceed250°C,whichitneverdid(maximumwas90°C).Allexternalweldswere e-beam welded while all internal welds were laserwelded.After our initial development of the P-DP (combined or“1301”aswedesignated it) sensor, Figure1a,we learnedthattherewerenoCMPeffects,[5-6],therebyallowingusto separate the combined P-DP functions from a single,large,sensorpackaging,intotwoseparateP,DPsensorcellsFigure1b-d.ThisalsoenabledustoreducethepackagingoftheoriginalP-DP(1301,combined)sensorinhalfleadingtothesmaller,individualPandDPsensorMEMSdiehousedina1”ODsensorpackaging.Thissmallerpackagingexpandedtheir potential application to the downhole environment.The sensor bodies/cells for the separate P, DP and MDSfunctionsareall thesame1”ODhousing,showninFigure1b;whatdiffersbetweenthemistheMEMSdiethatisusedinternally.Italsofollowsthattheendfittingsaredictatedbytheend-user;wedecidedtouseHF4(HiP)fittings.PreliminarySensorCalibrationResultsForallthesensors(P,DP,MDS)aseriesof5pointcalibrationtests included:MEMS die only (on T08 header, Figure 3);MEMSdieinstalledintopackaging(withnooil);andfinallysensortesting,withfullpackageassembled.TheMEMSdietests were conducted at ambient CMP, ambient sensortemperature.AllMEMSdietestshadtoshowgoodlinearityandlowtotaluncertaintybeforeinstallationintothesensorpackagingandbeforeproceedingwithweldingoperations.

AbsolutePressureSensors:Absolutetestsforthecombined,‘1301’,P-DPsensor,Figure1a,werepresentedinpreviouspapersbytheauthors,[5-6].Our teamworkedonreducing the formfactor (i.e.overallOD)of the1301P-DPsensor toarriveatapackaging thatwashalfthesize,downto1”OD.InthathousingweinstalledourabsoluteMEMSdie.Thatsensor,designatedthe4304-P-3F,Figure1c,wastested,forthefirsttime,upto19,700psia. No leaks were observed through any of the welds,howeveraslightoilleakappeared,above12,000psi,attheelectricalport,affectingthesensor’sperformance.Ourteam


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hassometheoriesastohowthatmayhaveoccurred,andiscurrentlyassessingasolution.Weanticipatethatoursecondabsolutesensor,designated4304-P-5F,willundergotestinginthenearfuture,withbetterresults.

DifferentialPressureSensors:Ourdifferentialpressuresensor(“4304”)ispackagedinthe1”ODhousingshowninFigure1b,withHF4endfittings.The4304 DP sensors all have the same 0-75 psid MEMS die,whichleveragesafullWheatstonebridgeconfiguration.InitialtestsshowedthatCMPvariationsdidnotaffecttheDPmeasurement,allowingforaDPsensoranditsDPMEMSdieto be housed in its own packaging, without the need tosimultaneously measure (and therefore correct for) CMP,eliminatingtheneedfortheMEMSPdietobesituatednextto theDPMEMSdie in the samepackaging, aswas donepreviously,Figure1a.For the differential pressure units, each test series wasperformedwithapplicationofadifferentialpressure(0-75psid,etc)atambienttemperatureforagivenCMP,startingatambientCMP.CalibrationswerealsocontinuedtohigherCMPsupto15,000psia.StartingatzeroDP,fiveincreasingDPswouldbeattainedtoamaximumof80psid,theneachsameDPwouldbeattainedindecreasingorderdownto0psid. This cyclewas repeated a second time, allowing thedeterminationofhysteresisandrepeatabilityandthereforetotaluncertainty.Initialfivepointcalibrationresultsshowedthattherewere:(i) noCMPeffects on theDPmeasurements; and (ii) verylineartemperatureeffects,asper[6].Theseexcellentresultsallowed for differential pressure measurements with noCMP corrections and with simple, algebraic equations tocorrect for temperature as opposed to multi-coefficientpolynomial temperature correction terms. Based on this,our teamproceeded to investigate the turndownratioofthis0-75psidMEMSdie,forthedifferentialsensorsinoursuite. The resultswere equally good, as shown Figure 4,wherewepresentcalibrationdatafor0-75psid,0-25psid,0-15psidand0-5psidtakenatambientCMPandambientsensortemperature.Thedatashowsexcellentturn-downcapabilitiesof theDPsensor as well as good linearity, repeatability, totaluncertainty for constant sensitivity of 0.653 mV/psid or0.131mV/psid/Vexc,whereVexcisaconstant5Vdcexcitationvoltage,Figure4c.Despitetheverygoodturndown,theFSOoutputoftheDPsensor,forthelowestdifferentialpressureof0-5psidwasvery low,~3-4mV.Inorderto improveonthis,formuddensitysensorapplications,theteamre-visitedtheMEMSdiedesignandre-designeditforlowerDPranges,eg.0-5psid.

MDSSensors:Formuddensitysensor(MDS)applicationswere-designedtheMEMS die for 0-5 and 0-15 psid full scale range, fullWheatstone bridge using our design/analysis tools, whichare anchored with experimental data. Two MDS sensorswere fabricated but only one has remote seals/capillarytubes installed as of this writing. As with the DP (4304)sensors,oneMDSsensorunderwentthefollowingfivepointcalibration tests:MEMS die only,MEMS die installed intohousing (no oil); MDS sensor without remote seals andfinallyMDSsensorwithremoteseals.PreliminarydatawasobtainedandispresentedinFigure5,whereweseethattheMDSexhibitsexcellent linearityand repeatability,minimalhysteresis, with a total uncertainty of 0.0071% FS (w/oremote seals). Note that the initial set of five pointcalibration tests were conducted at CMP = ambientpressure,withthesensoratambienttemperature.Withtheremote seals, the total uncertainty increases to about0.0098%;weexpectedadegradationinsensorperformanceafterinstallationofremoteseals.Thesensor’ssensitivityof0.274mV/psid/Vexcisinlinewithourmodelpredictions.These results are promising, with regards to potentiallyutilizing the MDS sensor in downhole applications tofunction as a kick detection sensor by measuring minutechanges inmuddensity,asdiscussedlater.Anestimateofthehydrostatichead,DP,assumingaseparationdistanceof3feetbetweentheremoteseals,forseveralmuddensities,ispresentedinTable1.Wethereforeexpect~3.6mVFSOfortheMDSsensorfor17ppgmuddensity.Presently, the team is preparing for continued calibrationtestingoftheMDSsensorsaswellasthefollowingteststobe conducted in the Mud Sensor Static Test Stand, atInnoveering, Figure 6 : (i) test with air only; (ii) test withwater only; (iii) test withmud only and (iv) variablemuddensity. We will purchase appropriately mixed mud, i.e.dieselbasedmudsystem,withdieseloil,water,emulsifier,salt,lime,viscosifier,andbarite.Initialmeasurementsofthemuddensity,alongwithinsitutemperaturemeasurements,willbemadebyusingthegravimetricmethodtocomparetotheMDS sensor densitymeasurement. The procedure formanuallyincreasingthemuddensityby1ppgistoaddabout7.67lbmofbaritetotheexistingmixture.HPHTApplications:As unconventional oil and gas exploration venturesmoveinto subsea/downhole environments that are HPHT, theneed for reliable instrumentation that can survive andperformintheseapplicationswillbecomecritical.OurP,P-DP,DPandMDSsensorsuitecouldenhanceseveralHPHTapplications,byextendingtherangeofproductsusedbysubseaengineers/operators,asbrieflydiscussedbelow.


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Upstream:MPFM

Numerous manufacturers of MPFM utilize a suite of wellengineered components to measure the volumetric flowrateofmultiphasefluidsintheonshorepipelines,Figure7a, that lead to and from the refineries, etc. In addition,offshore pipelines/manifolds in the Gulf of Mexico,transportmultiphasefluidstotheContinentalUnitedStates.TheseMPFMsalsomeasurethewatercut,gascut,salinityandother importantparametersthatarerequiredtobackout themeasurementsof thebulk fluid’sconstituents, i.e.theoil,gasandwaterparameterstoassesswhatpercentageof the total volumetric flow rate isoil. Typically, invertedventuris are among some of the components within theMPFM. Such unchoked venturis require a differentialpressuremeasurement across the venturi plenum and itsthroat.SubseaMPFMssometimesusetwosingle,absolutepressuremeasurementstoobtaintheDPacrosstheventuri.Obtaining highly accurate DP measurements, with twoabsolutesensors,particularlyathighCMPs(eg10,000psi)isdifficult and more than likely leads to some error in themeasurement.Thiscouldbeasignificanterror,especiallyincomingling pipelines, which are shared amongst severalend-users.Errorsintotalvolumetricflowrates,evenif1-2%can lead to substantial under or over-accounting of oilproduct revenue. It therefore follows that in HPHTenvironments, e.g. the 20 ksi/250°C environment, suchmethods of obtaining differential pressure may not beacceptable. In these cases, a HPHT differential pressuresensor, with 0.01-0.02% FS accuracy, across the invertedventure,withintheMPFM,couldbeverybeneficial.

Subsea:SmartWellheadsSubseaequipment,eg.ChristmasTrees,MPFMs,wellheads,Figure 7b, could all be good applications for our highlyaccurate HPHT P, DP sensors. Smart wellheads are beingpursued by numerous companies. Such smart wellheadsrequireP,DPsensorsfor[10]:• WellheadP,T:tomonitorthehealthofthewellandaidin

understandingthefluidcomposition;• WellAnnulusPressure:helpsmonitorcasingpressure,

wherebyapressureincreasewouldrequirewellrelief;• OilProductionTotalizedFlow:severalsensorsutilizedto

calculatetotalflowoutput,asdiscussedearlier,inthecaseofDPmeasurementsforMPFMs;

• InjectionWellheadMonitoring:P,TandDPmeasurementsprovidestatusoftheinjectionprocess;

• SteamInjectionHeatExchangerManagement:measurementsofPandDPacrossheatexchangersallowmonitoringoftheirperformance;

DownholeKickDetection

Ultimately, subsea engineering activities serve to ensurethattheoilproductisexplored,producedandtransportedinahighlyefficient,safeandreliablemanner,torefineries,storage depots, etc. The entire process is a choreographyand synchronization of drilling management, i.e.maintainingpressurebalance,controlledbytheadditionofmud(circulationfluid)toprovidethatbalance.Anarrayofextremely large equipment (eg BOP, ram, choke) arecontrolled by a fluidic “nervous system” of drill strings,pipleines,allmonitoredbysensors,withpredictiveanalysisdrivenbyalgorithmsandultimatelydecisionsmadebythesubsea engineers/operators. These operations areextremely dangerous with disastrous consequences if notperformedaccurately,timelyandreliably.The blowout accident is one of the most common anddangerous safety concerns. Typically, overflow is theprecursorofblowout, causedbyunbalancedBottomHolePressure (BHP) during the drilling process, [11]. Anunbalancedeventorencounterwithagaspocket,ultimatelyleads toa“kick”.Kickdetectionandmanaging/monitoringthe well during the drilling operation is a critical task. AsuddenchangeinmuddensitymaybetheresultoflostmudcirculationtothereservoirorformationcausingchangesintheannularpressureortheBHP.Suchchangesinpressurearemanagedbyaddingmudtothesystem.Currently,drillingoperationsaremonitoredbydetectingthemudlevelinoverflowtanksatthesurfaceandbymonitoringchangesinpressurebetweentheannulusandthedrillstring.Academiaandindustryarepresentlyworkingondownholekickdetectionsystems,[2-4;10-11].Severalcompaniesarealso making progress on “intelligent pipe/mud loggingtools”,wherethesesystemsprovidelogginginformationasthedrillprocessisoccurring.Some of the challenges with the current state of the art(CSOTA) mud monitoring systems are: (i) sometimes thecirculationloss(whichleadstomuddensitychange) istoosmall anddifficult todetect accurately; (ii) there canbealarge time lagbetweendownhole changes inmuddensityand pressure; and (iii) there are no downhole differentialpressuresensorswiththerequiredaccuracytodetectkick.Tomonitorthedrillingprocessandensureproperwellborepressurebalance,i.e.topreventkick,operatorswouldneedtimelyinformationaboutdownholeconditions(P,T)aswellasthemuddensityprofile,r(h,t),asafunctionofpositionin thedownholeenvironment ‘h’,and time.A lowdensitykick may occur in the downhole environment beforeanythingisdetectedatthesurface.ImplementinganarrayofaccurateHPHTDPsensorswithinthemudloggingtoolscouldassistindetectingkicksooner.Forexample,locatingHPHTMDSsensors,every20-30feet,alongthemudlogging


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toolcouldbeveryhelpfultothedrillingoperatorsobtainingtimelydataonthemuddensitychanges,whichwouldalsoprovideinformationonforecastingtheexpansionrateofthegas during a kick event. Such timely, accurate anddistributed sensing would allow for better drillingmanagementandwellcontrol(eg.changingtheBOPchokesettings toregulatethemudflowrate intoandoutof thewell)andisolatingthekicklocation.ConclusionsThis work represents the continued technologydevelopmentofourP,DP,MDSsensorsuiteforsubseaanddownhole applications with the following performanceresults:

• Tested to high pressures (15,000psi for theDP sensorsand19,700psiaforthePsensor).

• DP sensor exhibited excellent linearity, repeatability,minimal hysteresis, for constant sensitivity of 0.653mV/psidor0.131mV/psid/Vexc,whereVexcisaconstant5Vdc excitation voltage over DP of 0-75 psid. The datashows excellent turn-down capabilities from 0-75 psiddownto0-5psid.

• PreliminaryMDSsensordatashowsexcellentlinearityandrepeatability,minimalhysteresis,withatotaluncertaintyof 0.0071% FS (w/o remote seals) at ambient CMP andambientsensortemperature.Withtheremoteseals,thetotal uncertainty increases to about 0.0098%. TheMDSsensor’ssensitivityof0.274mV/psid/Vexcisinlinewithourmodelpredictions.

• DP sensor linearity and performance shows excellentlinearity, repeatabilityandminimalhysteresisup to250°C.

AreviewofsomeusefulapplicationsfortheP,DPandMDSsensorswasmade for upstreamMPFMs, subseawellheadinstrumentationanddownholekickdetection.

RecommendationsFurtherworkinthefollowingareasisrequiredfortheP,DPandMDSsensors:

• Continue performing 5 point calibration tests at severalCMPsupto15,000psia;

• Continueperformingtemperaturetestsupto250°C;• Testsensorresponsetime.• Conduct simultaneous high P and high T calibration

testing;• Perform a series of reliability tests as per industry

standards;• ReviewfailuremodesofMDS(eg.cakingofremoteseals)

andaddressaccordingly.

AcknowledgementsTheauthorswouldliketoacknowledgetherolesplayedbythe two major sponsors. First, the US Department ofEnergy’sNationalEnergyTechnologyLaboratory,throughitscontractor,RPSEA,providedthefundingandtheimpetusfornumerous deepwater technology developments, includingthisone.Andsecond,themembercompaniesoftheJointIndustry Project for 10121-4304-01 – Chevron,ConocoPhillips, GE, Innoveering, Statoil, and Total, whoprovidedtheco-fundingrequiredbyRPSEA,aswellas theexpertise in subsea and downhole engineering andmeasurementnecessarytosuccessfullycompletetheworkleadinguptothiseffort.In addition, we extend our gratitude to JamesM. Pappas(RPSEA)andRoyLongoftheDept.ofEnergy-NETLfortheirsupport.WearealsogratefultoJimFox(EBI)forhisexpertiseintherequiredweldingoperationsandAbelCrosbyandhisteamat Wika for their design and fabrication of the remotediaphragms.Nomenclature

P BHP = BottomHolePressure BOP = BlowOutPreventer CMP = CommonModePressure CSOTA= CurrentStateoftheArt DP = DifferentialPressure[psid] HPHT = HighPressureHighTemperatureP MDS= MudDensitySensor. MPFM= Multi-PhaseFlowMeter O&G= OilandGasT P = AbsolutePressure[psiaorpsig] SOI = Silicon-on-Insulator T = Temperature

Vexc = SensorExcitationVoltage[mV]

References1. OTC 2014: GE Introduces 20 ksi Deepwater Drilling

System”,OffshoreMagazine,5/7/2014.2. Willersrud,A.,Blanke,M.,Imsland,L.,andPavlov,A.,.A.

2015. Fault Diagnosis of Downhole Drilling IncidentsUsing Adaptive Observers and Statistical ChangeDetection,J.ofProcessControl,30,pp.90-103.

3. Downton, G., A Technical Perspective on the Currentand Future Challenges and Opportunities Facing theAutomation of Drilling, Drilling Systems AutomationTechnical Section, SPE International, Aberdeen, UK,October2,2014.

4. SekalAs,2012,ScandinavianOil-GasMagazine,No.7/8,pp.154-155.


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5. Hall, J.E., High Pressure/High Temperature SensorDevelopmentandQualification,OTC23218paper,OTCConference,Houston,TX,2012.

6. Hall,J.E.;Tiliakos,N.,;Brown,J.,Worst,T.,andFoster,R., True Downhole Measurement of DifferentialPressure, OTC 25772-MS paper, OTC Conference,Houston,TX,2015.

7. Hall, J.E., Improvements to Deepwater SubseaMeasurements RPSEA Program: High Pressure/HighTemperature Sensor Development and Qualification,OffshoreTechnologyConference,OTC-23318,30April-3May2012,Houston,TX.

8. Hall,J.E.,Miller,M.,Kliman,R.,SensorRedundancyforCritical Pressure Measurements, 37th InternationalInstrumentationSymposium,ISA,SanDiego,CA,1991.

9. SubseaWellhead(OffshoreTechnologyMagazine).10. Smart Wireless Solutions catalog, Emerson Process

Management.11. Ge, L., Hu, Z., Chen, P., Shi, L., Yang,Q., and Liao, J.,

ResearchonOverflowMonitoringMechanismBasedonDownhole Microflow Detection, MathematicalProblemsinEngineering,Vol.2014,ArticleID676290.


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(a)

(b)

(c)

(d)

(e)

Figure1:HPHTP-DP-MDSSensorSuite:(a)1301CombinationP-DPsensor;(b)4304DPSensor(w/oendfittings);(c)4304Psensorw/endfittings;(d)MDSsensorwithendfittings(w/oRemote Seals); and (e) MDS Sensor with end fittings andRemoteSeals.

(a)

(b)

(c)

Figure2:(a)Metrologystation;(b)metrologydatabeforeandafter welding sensor isolation diaphragms; and (c) DeadWeightandOvenTestequipmentatInnoveering’sLaboratory

Figure3:Photosof: (left)absolutepressureMEMSdie;and(right)differentialpressureMEMSdieonT08headersfor“dieonly”5ptcalibrationtesting.

MDSSensorHousing

SensorEndFittingsSensorEndFittings

RemoteSeals(dh=3ft)

MDSSensor

BeforeWeld(Orange)AfterWeld(Blue)


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(a)

(b)

(c) Figure4:Calibrationdataforthe4304DPsensorshowingaturndownratioof15:1:(a)0-5psid;(b)0-75psid;and(c)intermediateDPpointsforbothsidesofthesensor,i.e.

positive(HI)sideandnegative(LO)side.

Figure5:FivepointcalibrationdataforourMDSsensorwithoutremotesealsattached.

Table1:TableshowingexpectedDPandMDSFSOforvariousmuddensities.

Figure6:TestStandforMudSensorStaticTestingatInnoveering

y=0.653x- 9E-05R²=1

y=-0.653x+0.0001R²=1

-4

-3

-2

-1

0

1

2

3

4

0 1 2 3 4 5 6

CorrectedSensorOutpu

tVoltage[m

V]

AppliedDifferentialPressure,DP[psid]

4304-2FDPSensorOutputvsAppliedDPNote:Datataken@AmbientCMP,T

Vout(mV)_Pos-Side-Corr2Vout(mV)_NegSide-Corr2Linear(Vout(mV)_Pos-Side-Corr2)Linear(Vout(mV)_Pos-Side-Corr2)Linear(Vout(mV)_NegSide-Corr2)Linear(Vout(mV)_NegSide-Corr2)

PROPRIETARY DATA

y=0.6527x+0.0071R²=1

y=-0.6532x- 0.0034R²=1

-60

-40

-20

0

20

40

60

0 10 20 30 40 50 60 70 80

CorrectedSensorOutpu

tVoltage[m

V]

AppliedDifferentialPressure,DP[psid]

4304-2FDPSensorOutputvsAppliedDPNote:Datataken@AmbientCMP,T

Vout(mV)_Pos-Side-Corr2

Vout(mV)_NegSide-Corr2

Linear(Vout(mV)_Pos-Side-Corr2)

Linear(Vout(mV)_NegSide-Corr2)

PROPRIETARY DATA

y=1.3677x- 0.1162R²=1

0

5

10

15

20

25

30

0 5 10 15 20 25

SENSO

ROUTP

UTVO

LTAG

E[MV]

APPLIEDPRESSURE[PSIA]

SensorVoltage_CORRECTEDforZeroOffsetANDVexc(mV)

Linear(SensorVoltage_CORRECTEDforZeroOffsetANDVexc(mV))

Mud Density (lbm/gal: ppg)

DP (psid) (for Dh=3ft)

Estimated MDS Sensor Output (mV)

0 0.00 0.00010 1.56 2.12717 2.65 3.61620 3.12 4.255


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(a)

(b)

(c)

Figure 7: Schematics of the various locations where HPHTpressuresensorsmaybeused:(a)onshoreinMPFMlines;(b)subsea in Christmas Trees, wellheads, subsea equipment(MPFM);and(c)downholeaspartofakickdetectionsystem,[9].

Documents

UPM 17010 Highly Accurate Pressure and Differential … · 23-02-2017 · tests included: MEMS die only (on T08 header, Figure 3); MEMS die installed into packaging (with no oil);