Systems and Methods for Distributed Downhole Sensing Using a Polymeric Sensor System

Abstract

Systems and methods for distributed downhole sensing in which a polymeric sensor system is coupled to one or more pieces of downhole equipment. The polymeric sensor system has multiple electric or nano sensors embedded in a polymeric material such as a tape that can be applied to the downhole equipment to sense parameters at multiple, physically distributed locations. A monitoring unit at the surface of the well may receive data from the embedded sensors. A control unit at the surface of the well may communicate control information through the polymeric sensor system to electrically controlled equipment downhole, eliminating the need for a control line that is separate from the polymeric sensor system.

What is claimed is: 
     
         1 . A downhole sensing system comprising:
 one or more pieces of monitored downhole equipment positioned within a well; and   a polymeric sensor system coupled to the pieces of monitored downhole equipment,
 wherein the polymeric sensor system includes a plurality of sensors embedded in a polymeric material, and 
 wherein the sensors are positioned in the polymeric material to sense parameters at multiple, physically separate locations. 
   
     
     
         2 . The system of  claim 1 , further comprising a surface monitoring unit coupled to the polymeric sensor system and configured to receive sensor data from the polymeric sensor system. 
     
     
         3 . The system of  claim 1 , wherein the polymeric sensor system comprises a polymeric tape having a plurality of networked sensors embedded therein, wherein the sensors are selected from the group consisting of: electric sensors; and nano sensors. 
     
     
         4 . The system of  claim 3 , wherein the one or more pieces of monitored downhole equipment comprise a completion, wherein the sensors of the polymeric sensor system are configured to measure strain, and wherein the polymeric sensor system is helically wrapped around the completion. 
     
     
         5 . The system of  claim 4 , wherein the polymeric sensor system is coupled to a surface monitoring unit and configured to convey measured strain data to the surface monitoring unit, wherein the surface monitoring unit is configured to analyze the strain data and thereby detect deformation of the completion. 
     
     
         6 . The system of  claim 1 , further comprising a monitoring unit coupled to the polymeric sensor system and configured to receive sensor data from the polymeric sensor system, wherein the monitoring unit is positioned within the well. 
     
     
         7 . The system of  claim 1 , further comprising a control unit coupled to the polymeric sensor system and configured to receive sensor data from the polymeric sensor system, wherein the control unit is positioned within the well and configured to control one or more pieces of the downhole equipment without intervention from equipment positioned at the surface of the well. 
     
     
         8 . The system of  claim 1 , wherein the polymeric sensor system is incorporated into at least one of the pieces of monitored downhole equipment during manufacture of the at least one piece of monitored downhole equipment. 
     
     
         9 . The system of  claim 1 , wherein the sensors in the polymeric material are positioned at locations which are axially spaced along the length of the monitored downhole equipment. 
     
     
         10 . The system of  claim 1 , wherein the polymeric sensor system comprises a set of sensors forming a multi-dimensional sensor array in the polymeric material. 
     
     
         11 . The system of  claim 1 , wherein the polymeric sensor system includes multiple sensor arrays that are electrically interconnected. 
     
     
         12 . The system of  claim 11 , wherein the polymeric sensor system extends over multiple sections of production tubing. 
     
     
         13 . The system of  claim 1 , wherein the polymeric sensor system is configured to convey sensor data in a first direction to a surface monitoring unit and to convey control information in a second direction opposite the first direction to a piece of electrical downhole equipment. 
     
     
         14 . The system of  claim 1 , wherein the one or more pieces of monitored downhole equipment comprise a flexible joint, wherein the polymeric sensor system includes strain sensors that are positioned around the flexible joint, and is configured to provide a strain profile of the joint, wherein the polymeric sensor system is coupled to a data processor that is configured to map a wellbore of the well based on the strain profile. 
     
     
         15 . A downhole sensing method comprising:
 providing a polymeric sensor system, wherein the polymeric sensor system includes a plurality of sensors embedded in a polymeric material;   positioning the polymeric sensor system on one or more pieces of monitored downhole equipment;   positioning the monitored downhole equipment in a well; and   retrieving data from the polymeric sensor system.   
     
     
         16 . The method of  claim 15 , wherein providing the polymeric sensor system comprises polymeric tape having a plurality of networked sensors embedded therein. 
     
     
         17 . The method of  claim 16 , wherein the one or more pieces of monitored downhole equipment comprise a completion, wherein the sensors of the polymeric sensor system are configured to measure strain, and wherein the polymeric sensor system is helically wrapped around the completion. 
     
     
         18 . The method of  claim 17 , further comprising monitoring strain data from the polymeric sensor system, analyzing the strain data and detecting deformation of the completion. 
     
     
         19 . The method of  claim 15 , further comprising the polymeric sensor system sensing parameters at multiple, physically separate, axially spaced locations on the monitored downhole equipment. 
     
     
         20 . The method of  claim 15 , further comprising communicating control information to one or more pieces of electrical downhole equipment through the polymeric sensor system. 
     
     
         21 . The method of  claim 15 , wherein positioning the monitored downhole equipment in the well comprises positioning the monitored downhole equipment in a producing or injection zone of the well. 
     
     
         22 . The method of  claim 15 , wherein the plurality of sensors comprise strain sensors, wherein positioning the polymeric sensor system on the one or more pieces of monitored downhole equipment comprises positioning the polymeric sensor system around a flexible joint, the method further comprising generating a strain profile of the joint with the polymeric sensor system and map a wellbore of the well based on the strain profile.