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US20150330212A1 - Self-powered microsensors for in-situ spatial and temporal measurements and methods of using same in hydraulic fracturing - Google Patents

Self-powered microsensors for in-situ spatial and temporal measurements and methods of using same in hydraulic fracturing Download PDF

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Publication number
US20150330212A1
US20150330212A1 US14/713,130 US201514713130A US2015330212A1 US 20150330212 A1 US20150330212 A1 US 20150330212A1 US 201514713130 A US201514713130 A US 201514713130A US 2015330212 A1 US2015330212 A1 US 2015330212A1
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Prior art keywords
microsensors
module
delayed
sensor system
microsensor
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US14/713,130
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Inventor
Mohamed Ben Mahmoud Sassi
Manhal Sirat
Irfan Abdulqayyum Saadat
Rashid Kamel Abu Al-Rub
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Abu Dhabi Co For Onshore Petroleum Operation Ltd
Khalifa University of Science, Technology and Research (KUSTAR)
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Masdar Inst of Science and Tech
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Priority to US14/713,130 priority Critical patent/US20150330212A1/en
Assigned to MASDAR INSTITUTE OF SCIENCE AND TECHNOLOGY reassignment MASDAR INSTITUTE OF SCIENCE AND TECHNOLOGY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIRAT, MANHAL, ABU AL-RUB, RASHID KAMEL, SASSI, MOHAMED BEN MAHMOUD, SAADAT, IRFAN ABDULQAYYUM
Publication of US20150330212A1 publication Critical patent/US20150330212A1/en
Assigned to Khalifa University of Science and Technology reassignment Khalifa University of Science and Technology ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MASDAR INSTITUTE OF SCIENCE AND TECHNOLOGY
Priority to US16/204,301 priority patent/US10880625B2/en
Assigned to ABU DHABI COMPANY FOR ONSHORE PETROLEUM OPERATION LIMITED reassignment ABU DHABI COMPANY FOR ONSHORE PETROLEUM OPERATION LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Khalifa University of Science and Technology
Assigned to Khalifa University of Science and Technology, ABU DHABI COMPANY FOR ONSHORE PETROLEUM OPERATION LIMITED reassignment Khalifa University of Science and Technology CORRECTIVE ASSIGNMENT TO CORRECT THE ASSIGNEE NAME PREVIOUSLY RECORDED AT REEL: 053961 FRAME: 0575. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Assignors: Khalifa University of Science and Technology
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04Q—SELECTING
    • H04Q9/00—Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B5/00—Measuring for diagnostic purposes; Identification of persons
    • A61B5/05—Detecting, measuring or recording for diagnosis by means of electric currents or magnetic fields; Measuring using microwaves or radio waves
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B41/00—Equipment or details not covered by groups E21B15/00 - E21B40/00
    • E21B41/0085—Adaptations of electric power generating means for use in boreholes
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25—Methods for stimulating production
    • E21B43/26—Methods for stimulating production by forming crevices or fractures
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25—Methods for stimulating production
    • E21B43/26—Methods for stimulating production by forming crevices or fractures
    • E21B43/267—Methods for stimulating production by forming crevices or fractures reinforcing fractures by propping
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/06—Measuring temperature or pressure
    • E21B47/065—
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/06—Measuring temperature or pressure
    • E21B47/07—Temperature
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/10—Locating fluid leaks, intrusions or movements
    • E21B47/11—Locating fluid leaks, intrusions or movements using tracers; using radioactivity
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
    • E21B47/13—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
    • E21B47/138—Devices entrained in the flow of well-bore fluid for transmitting data, control or actuation signals
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/26—Storing data down-hole, e.g. in a memory or on a record carrier
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04Q—SELECTING
    • H04Q2209/00—Arrangements in telecontrol or telemetry systems
    • H04Q2209/80—Arrangements in the sub-station, i.e. sensing device
    • H04Q2209/88—Providing power supply at the sub-station
    • H04Q2209/886—Providing power supply at the sub-station using energy harvesting, e.g. solar, wind or mechanical

Definitions

  • the present invention relates to microsensors and more particularly, to microsensors for in-situ spatial and temporal measurements and methods of using same in hydraulic fracturing.
  • Sensors are used in a wide range of applications for measuring various conditions. Designing sensors that are capable of operating and obtaining the desired measurements in certain environments and applications may be a challenge. In some applications, for example, the sensors must be a small size to be positioned in the environment where the conditions are to be measured. Sensors may also be damaged by environmental factors, such as high temperatures, high pressures, and corrosive materials.
  • Hydraulic fracturing is the fracturing of rock by a pressurized liquid and is commonly known as “fracking.”
  • hydraulic fracturing involves two steps. In the first step, water is mixed with sand and chemicals, and the mixture is injected at high pressure (e.g., 1500 to 3000 PSI) into a wellbore to create small fractures (typically around several mm in width). Fluids such as gas, petroleum, uranium-bearing solution, and brine water may migrate along these fractures to the well.
  • the hydraulic pressure is removed from the well, and small grains or particles of proppant (e.g., sand or aluminum oxide) are injected to hold these fractures open once the rock achieves equilibrium.
  • proppants may include spherical balls with a radius of 3-4 mm and made of ceramic and/or other hard materials. Because of the size and shape of the proppants, fluid may diffuse out of the fractures or cracks.
  • FIG. 1 is a schematic diagram of microsensors being injected into a well during a hydraulic fracturing operation, consistent with an embodiment of the present disclosure.
  • FIG. 2 is a schematic diagram of microsensors located in fractures formed by the hydraulic fracturing operation, consistent with an embodiment of the present disclosure.
  • FIG. 3 is a perspective view of microsensors consistent with at least one embodiment of the present disclosure.
  • FIG. 4 is a perspective view of a plurality of microsensors encapsulated with a group coating.
  • FIG. 5 is a schematic diagram of a system/network of microsensor nodes comprising a plurality of microsensors.
  • FIG. 6 is a schematic diagram of a supersensor/satellite sensor system.
  • FIG. 7 is a schematic diagram of a satellite/node sensor system.
  • FIG. 8 is a schematic diagram of a plurality of microsensors forming a cluster system.
  • FIG. 9 is a schematic diagram of a microsensor including an electrochemical energy harvester module.
  • Microsensors may be used for in-situ spatial and temporal measurements.
  • the microsensors may include self-powered microsensors.
  • self-powered refers to the capability of the microsensor to generate sufficient power to operate the electronics in the microsensor, for example, by harvesting energy in the environment.
  • Embodiments of self-powered microsensors generally include one or more sensor elements for measuring conditions, data processing circuitry for processing data (e.g., sensor data from the sensor elements and/or location data from other microsensors or transmitters), circuitry for storing, transmitting and/or receiving data, and an energy harvester for self-powering the sensor elements and circuitry.
  • the microsensor design e.g., the types of sensor elements, the type of energy harvester, or the type of circuitry
  • the microsensor design may depend on the particular application for the microsensor.
  • a plurality of self-powered microsensors may be used together for measuring conditions at locations throughout an environment being monitored and/or for mapping the environment.
  • a plurality of self-powered microsensors 10 a - n may be used for measurements during and after hydraulic fracturing (also referred to as “fracking”).
  • a plurality of self-powered microsensors 10 a - n may be injected into a well bore 12 .
  • the microsensors 10 a - n may be injected (e.g., introduced) into the well bore 12 together with a fluid 14 for monitoring the dynamics of the fracturing process.
  • the microsensors 10 a - n may be used, for example, with tomography techniques to map the shape of the reservoir before, during, and/or after the fracking process.
  • the fluid 14 with which the microsensors 10 a - n may be introduced into the well bore 12 may include, but is not limited to, a fracking mixture.
  • the fracking mixture may include any fracking mixture known to those skilled in the art for creating factures in the rock under high pressure.
  • the fracking mixture may include a mixture of water and chemical additives.
  • the chemical additives may include, but are not limited to, one or more of the following:
  • a plurality of self-powered microsensors 10 a - n may also be injected together with proppants 200 a - n (e.g., after the fracking process) into the fractures or cracks 210 after the fracturing occurs to monitor production of oil and/or for measuring conditions, such as temperature, pressure, and presence of oil.
  • the proppants 200 a - n may include any material(s) configured to be embedded into and/or keep fractures/cracks open to allow gas/fluids to flow more freely to the well bore.
  • the proppants 200 a - n may include, but are not limited to, one or more of sand (including sintered bauxite, zirconium oxide) and/or ceramic beads. It should be appreciated that the proppants 200 a - n and microsensors 10 a - n may be separate from, or included in, the fracking mixture 14 .
  • the microsensor 10 a - n may have a size and shape consistent with the form factor of the proppants 200 a - n , for example, a spheroid or spherical shape may range from 1 mm to 20 mm in size.
  • the plurality of self-powered microsensors 10 a - n may be configured to generate wireless signals (e.g., ping signals such as, but not limited to, an RF electromagnetic wave) which includes the sensor collected data.
  • the ping signals may optionally include a unique ID and/or location parameters.
  • the microsensors 10 a - n may transmit ping signals periodically (e.g., at fixed time intervals such as, but not limited to, 5 minutes) and/or based on one or more threshold values (e.g., a power supply threshold and/or buffer threshold).
  • the microsensors 10 a - n if the power supply is below a threshold, the microsensors 10 a - n may wait until the power supply reaches and/or exceeds the power supply threshold. Alternatively (or in addition), the microsensors 10 a - n may wait until the data stored in a buffer and/or memory (e.g., sensor data from one or more microsensors 10 a - n ) reaches and/or exceeds a buffer/memory threshold.
  • a buffer and/or memory e.g., sensor data from one or more microsensors 10 a - n
  • the microsensor 10 may include one or more sensor modules 310 , at least one processing circuitry 312 (e.g., but not limited to, one or more CPUs, circuitry, processors, logic, or the like), at least one wireless communication module 314 , at least one data storage/signal processing module 316 , at least one energy harvester module 318 , and/or at least one memory 320 .
  • the microsensor 10 also include a support body/structure 302 configured to support sensor modules 310 , processing circuitry 312 , wireless communication module 314 , data storage/signal processing module 316 , energy harvester module 318 , and/or memory 320 . It should be appreciated that the microsensor 10 shown in FIG. 3 is for illustrative purposes, and that one of ordinary skill in the art (upon reading the present disclosure as a whole) will understand that various functions and/or components may be combined and/or eliminated.
  • An individual microsensor 10 may include cubical or cuboid shaped structure, though other shapes are possible such as, but not limited to, spherical, oblong, and the like.
  • One or more microsensors 10 a - n may be covered and/or encapsulated with a coating as described herein.
  • the coating may have a form a spherical or spheroid shaped.
  • a the terms “cube,” “cubical,” and “cuboid” do not require a perfect cube shape and the terms “sphere,” “spherical,” and “spheroid” do not require a perfect sphere shape.
  • the microsensor 10 may be made out of graphene, carbon nanotubes and/or similar materials. These materials have demonstrated thermal stability up to 700° C. and also are chemically inert such that they can detect the presence of other materials without chemically reacting with them. For higher temperature requirements, sensors made from GaN be used, which can withstand temperatures up to ⁇ 900 C.
  • the sensor module 310 may include one or more sensors and/or sensor arrays.
  • the sensors may include, without limitation, temperature sensor elements, pressure sensor elements, stress sensor elements, pH sensor elements, and chemical composition sensor elements.
  • the sensor module 310 may include a sensor array with sensors tuned to detect the target physical and chemical properties of the environment in the fractures or cracks.
  • the target physical properties may include pressure and/or stress in the rock formation and other environmental properties in steady state/production.
  • a cubical or cuboid shaped microsensor 10 may be capable of measuring stress in three axes (e.g., ⁇ 1 , ⁇ 2 , and ⁇ 3 ), for example, by using sensor elements on at least three faces of the cuboid structure.
  • these sensors may also be made out of GaN, graphene, carbon nanotubes and similar materials. These materials have demonstrated thermal stability from 700° C. (in case of carbon nanomaterials) to 900° C. (in case of GaN).
  • the carbon nanomaterials are chemically inert such that they can detect the presence of other materials without chemically reacting with them.
  • the processing circuitry 312 may be configured to process and cause data to be stored, for example, in memory 320 (such as, but not limited to, a buffer or the like).
  • the processing circuitry 312 may be configured to process data generated by the sensor module 310 with time data (e.g., time data corresponding to sensor data generated by the sensor module 310 ), sensor type data (e.g., data associated with and/or identifying each sensor and/or type of sensor in the sensor module 310 ), location data corresponding to the position/location of the microsensor 10 , and/or microsensor identification data which uniquely identifies the microsensor 10 , and cause one or more of the data to be stored in the memory 320 .
  • time data e.g., time data corresponding to sensor data generated by the sensor module 310
  • sensor type data e.g., data associated with and/or identifying each sensor and/or type of sensor in the sensor module 310
  • location data corresponding to the position/location of the microsensor 10
  • microsensor identification data which uniquely
  • the processing circuitry 312 may also be configured to determine and/or approximate the position of the microsensor 10 .
  • processing circuitry 312 may also be configured to provide telemetry and/or triangulation based on pinging signals to or from two probes (e.g., in two wells) and/or other location based signals.
  • the processing circuitry 312 may include high temperature electronics based circuits capable of operating on low power.
  • High temperature electronics can be made out of GaN, which can operate in temperatures up to 900° C., and silicon on insulator (SOI) circuits, which can operate in temperatures up to 200° C.
  • the processing circuitry 312 may be configured to receive the data from the sensor module 310 , wireless communication module 314 , data storage/signal processing module 316 , and/or memory 320 , processes the data, and sends the data to a storage element (e.g., memory 320 ) and/or the wireless communication module 314 .
  • the data may be used to create temporal and spatial map for a given property or metric during the fracking process.
  • Processing circuitry 312 may also process data for telemetry and/or triangulation based on an external pinging signal.
  • a communication module 314 may be configured to cause one or more signals to be transmitted.
  • the communication module 314 enables wireless communications for the transfer of data to and/or from the microsensor 10 to one or more microsensors, nodes, supersensors, collection/processing controllers, and/or external devices.
  • the term “wireless” and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium.
  • Communication module 314 may implement any of a number of wireless standards or protocols, including, but not limited to, Wi-Fi (IEEE 802.11 family), WiMAX (IEEE 802.16 family), IEEE 802.20, long term evolution (LTE), Ev-25 DO, HSPA+, HSDPA+, HSUPA+, EDGE, GSM, GPRS, CDMA, TDMA, DECT, Bluetooth, derivatives thereof, as well as any other wireless protocols that are designated as 3G, 4G, 5G, and beyond.
  • Communication modules 314 may therefore include hardware to support wireless communication, e.g., one or more transponders, antennas, BLUETOOTHTM chips, personal area network chips, near field communication chips, wired and/or wireless network interface circuitry, combinations thereof, and the like.
  • the microsensor 10 may include a plurality of communication modules 314 .
  • a first communication module 314 may be dedicated to shorter range wireless communications such as Wi-Fi and Bluetooth and a second communication module 314 may be dedicated to longer range wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE, Ev-DO, and others.
  • the communication module 314 may be capable of sensing (e.g., receiving) acoustic pinging signals or RF beacons for telemetry applications. In addition or alternatively, the communication module 314 may be capable of transmitting a pinging signal. For example, the communication module 314 may be configured to transmit one or more pinging signals to fixed locations to provide a triangulation capability for obtaining location data.
  • the data storage/signal processing module 316 may be configured to store and/or process data.
  • the data storage/signal processing module 316 may be configured to store data generated by the sensor module 310 , processed by the processing circuitry 312 , and/or received by the communication module 314 .
  • the data storage/signal processing module 316 may store data from a plurality of different sources (e.g., but not limited to, the sensor module 310 , the processing circuitry 312 , and/or the communication module 314 ) and/or store data from one or more sources over time until a threshold amount of data and/or time period has been reached and/or exceeded.
  • the data storage/signal processing module 316 may also be configured to cause the collected/stored data to be consolidated into one or more ping signals.
  • the data storage/signal processing module 316 may be configured to cause the collected data to be stored in a single packet (e.g., the payload of a single packet) of a ping signal that be may be transmitted by the communication module 314 .
  • the header of the ping signal may identify the destination address and/or the source of the ping signal.
  • all of the data may not fit all within the payload of a single packet. As such, the data may be split and stored in two or more payloads of two or more packets.
  • the data storage/signal processing module 316 may also be configured to process and/or condition the data from one or more different sources (e.g., but not limited to, the sensor module 310 , the processing circuitry 312 , and/or the communication module 314 ).
  • processing and/or signal conditioning that the data storage/signal processing module 316 may perform include filtering, amplifying, signal-to-noise reduction, signal isolation, encoding, decoding, encryption, decryption, and/or the like. It may be appreciated that the data may also (or alternatively) be externally processed, for example, for purposes of creating an image using location data.
  • the energy harvester module 318 may harvest energy (also known as power harvesting or energy scavenging) from the environment such as kinetic energy, thermal energy, electromagnetic energy, salinity gradients, pH gradients, temperature gradients, and/or electrochemical energy and optionally store the energy (for example in one or more capacitors, super capacitors, batteries, and/or the like).
  • a microsensor 10 may also include a self-contained energy source such as a thin film battery.
  • an energy harvester module 318 includes electrochemical and/or thermoelectric generators (TEGs).
  • TEGs may include two ore more dissimilar materials coupled together to form a junction in the presence of a thermal gradient. The voltage may be increased by connecting a plurality of junctions electrically in series and thermally in parallel.
  • Thermal energy harvesters or electrochemical energy harvesters may be used.
  • One example of a thermal energy harvester includes two different alloy metals, which produce a voltage drop when placed across a temperature gradient.
  • the energy harvester module 318 may include an electrochemical energy harvester.
  • An electrochemical energy harvester may include dissimilar metals that form an electrochemical cell in the presence of ionic fluid in the environment in which they are used. If the microsensors 10 only include vibration based energy harvester modules 318 , the microsensors 10 may become dormant after the fracking process until they are brought to the surface. If the microsensors 10 include thermal energy harvester modules 318 and/or electrochemical energy harvester modules 318 , the microsensors 10 may be activated and powered when the microsensors 10 are stationary after the fracking process even without movement or vibrations.
  • an energy harvester module 318 includes piezoelectric crystals or fibers which generate a voltage whenever they are mechanically deformed. Vibration from the surrounding environment can stimulate piezoelectric materials, thereby generating an electrical current or voltage. For example, piezoelectric materials may convert mechanical strain into electric current or voltage. Vibration based energy harvester module 318 may take advantage of the vibration during the actual fracking process. Thus, the microsensors 10 may be energized as they move down the well and during the fracking process.
  • a vibration based energy harvester module 318 includes known energy harvesters based on AlN and capacitve sensors.
  • an energy harvester module 318 may include pyroelectric materials.
  • Pyroelectric materials convert a temperature change into electric current or voltage. It is analogous to the piezoelectric effect, which is another type of ferroelectric behavior. Pyroelectricity requires time-varying inputs and may suffer from small power outputs in energy harvesting applications due to its low operating frequencies.
  • one key advantage of pyroelectrics over thermoelectrics is that many pyroelectric materials are stable up to 1200° C. or higher, enabling energy harvesting from high temperature sources and thus increasing thermodynamic efficiency.
  • the energy harvester module 318 may include electrostatic (capacitive) energy harvesters. Electrostatic energy harvesting is based on the changing capacitance of vibration-dependent capacitors. Vibrations separate the plates of a charged variable capacitor, and mechanical energy is converted into electrical energy.
  • the energy harvester module 318 may include magnetic induction circuits. For example, movement of one or more magnets relative to one or more conductors may electrical currents due to Faraday's law of induction.
  • an energy harvester module 318 may include metamaterial energy harvesters.
  • Metamaterial-based energy harvesters wirelessly convert electrical signals (such as, but not limited to, microwave signals, RF signals, Wi-Fi signals, satellite signals, or even sound signals or the like) to electrical current (greater than that of a USB device).
  • EAPs electroactive polymers
  • a further example of an energy harvester module 318 may include antennas configured to collect energy from stray radio waves.
  • the antennas may include a rectenna and/or a nantenna.
  • microsensor 10 may replace the energy harvester module 318 with one or more batteries. It should also be appreciated that while the sensor module 310 , processor 312 , wireless communication module 314 , data storage/signal processing module 316 , energy harvester module 318 , and memory 320 are illustrated as separate components, the functionality of one or more of these various components may be combined.
  • Memory 320 may be part of, and/or separate from, the data storage/signal processing module 316 , and may be used to store data and/or applications/software to be executed by the processing circuitry 312 .
  • the microsensor 10 may optionally eliminate the wireless communication module 314 , and instead may store all data generated by the sensor module 310 in memory and/or data storage/signal processing module 316 .
  • the microsensor 410 may be retrieved from the recirculated fluid after the fracking process and then read off-line to create an image/map of the well during the fracking dynamics.
  • the microsensor 10 may also include a wireless communication module 314 that can transmit the data to collection nodes, in addition to being configured to be read after being retrieved from the recirculated fluid.
  • each of the microsensors 10 may be sealed and resistant to high temperatures and corrosion and the interior of the microsensors may include high temperature electronics/circuitry and components.
  • one or more coatings 330 may cover at least a portion of an exterior surface of the microsensor 10 .
  • the one or more coatings 330 (either individually and/or collectively) may encapsulate the entire outer surface of the microsensor 10 .
  • the coating 330 may be dissolvable and the microsensors 10 may be activated when the coating dissolves.
  • the coating 330 may dissolve due to temperature, pH, and/or contact with water, glycol, acids, breakers, buffers/pH adjusting agents, stabilizers, corrosion inhibitors, crosslinkers, friction reducers, gelling agents, iron controls, solvents, and/or surfactants as described herein.
  • Non-limiting examples of dissolvable coatings 330 include polyamide, polyglycolide or polyglycolic acid, polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene glycol, polystyrenesulfonate, quaternized amine polymers, alkoxomers, thermally decomposing polymer films, PC polymer, cellulose, hydroxyethylcellulose, ethylcellulose, cellulose esthers, resins, cationic polyacrylamide, acrylate, aminoacrylate, alkyl PEG-20, and mixtures thereof.
  • the dissolvable coating 330 may therefore be triggered by the chemical environment, a predetermined set temperature, and/or expose the underlying sensor elements and/or energy harvesters, thereby activating the microsensors.
  • the thermal dissolvable coating 330 may be selected from a group consisting of a polyamide, polyglycolide or polyglycolic acid, polyvinyl alcohol, polyvinyl pyrrolidone, polyethylene glycol, polystyrenesulfonate, quaternized amine polymers, alkoxomers, and mixtures thereof.
  • a water dissolvable coating 330 may selected from a group consisting of a polymer, PC polymer, cellulose, hydroxyethylcellulose, ethylcellulose, cellulose esthers, resins, and mixtures thereof.
  • a pH dissolvable coating 330 may selected from a group consisting of a cationic polyacrylamide, acrylate, aminoacrylate, alkyl PEG-20, and mixtures thereof
  • a plurality of microsensors 10 may be separately coated with dissolvable coatings 330 .
  • the coatings 330 on different microsensors 10 may dissolve at different times and/or under different conditions to provide staggered microsensor activation.
  • the dissolvable coatings 330 may dissolve by using different materials and/or thicknesses to control the time for dissolving from 1 minute to 1 hour to 24 hours or longer.
  • the dissolvable coatings 330 may thus allow a tunable activation, for example, in a range of 6-24 hours for each individual microsensor 10 .
  • the overall lifetime of a collective group of microsensors 10 may thus be extended by staggering the activation of subsets of the microsensors 10 .
  • a plurality of microsensors 10 a - n may be combined and encapsulated by a coating 400 as generally illustrated in FIG. 4 .
  • the coating 400 may include one or more layers of material which may be the same and/or different.
  • one or more of the microsensors 10 e.g., 10 a , 10 b
  • a group coating 400 (which may include one or more layers of coating materials) may cover the plurality of microsensors 10 a - n .
  • one or more microsensors 10 a , 10 b may include an individual coating 330 (which may include one or more layers of coating materials).
  • the group coating 400 may dissolve to expose one or more microsensors (e.g., 10 n ) and/or individual coatings 330 covering one or more microsensors ( 10 a , 10 b ). The individual coatings 330 may then dissolve based on different conditions than the group coating 400 .
  • a plurality of the microsensors 510 a - n may communicate with each other to form a system/network of microsensor nodes 500 (e.g., the microsensors 510 a - n may operate as nodes in a sensor network 500 ).
  • the microsensors 510 a - n may be configured to transmit a ping signal to adjacent microsensors 510 a - n .
  • a microsensor 510 a - n which receives a ping signal from an adjacent microsensor 510 a - n may be configured to retransmit the ping signal of the adjacent microsensor 510 a - n , along with its own ping signal.
  • the process may be continued until the ping signals are received by a controller.
  • the microsensors 510 a - n may be configured to determine the shortest communication path to one or more collection/processing controllers, for example, based on their location data and/or unique identifier. As may be appreciated, the ability to determine the shortest transmission communication path(s) may allow the wireless communication module of the microsensor 510 a - n to transmit a lower strength/power ping signal, thereby reducing the power requirements of the microsensors 510 a - n .
  • the microsensors 10 a - n may be configured to retransmit up to a predetermined number of ping signals in order to avoid overloading any one particular microsensor 510 a - n , thereby reducing the power requirements of the microsensors 510 a - n .
  • the microsensors 510 a - n may be configured to either periodically transmit/retransmit the ping signals and/or may transmit/retransmit the ping signals upon reach a threshold (e.g., supply power and/or buffer thresholds).
  • the supersensor/satellite sensor system 600 may include one or more (e.g., a plurality of) satellite microsensors 610 a - n in communication with one or more supersensor microsensors 612 .
  • the supersensors 612 may form the backbone in the supersensor/satellite sensor system 600 through which data transmitted by their respective satellite sensors 610 a - n is collected, processed and transmitted.
  • the satellite sensors 610 a - n may be configured to generate and transmit ping signals including the sensor data and optionally location information and/or a unique identifier.
  • the plurality of satellite sensors and/or supersensors may include, but not limited to, sensing functions like temperature, pH, pressure (e.g., but not limited to, pore-water pressure), stress, magnetic field strength, chemical composition, and/or various stresses within the fractured rock and any formation change data as described herein.
  • the supersensor 612 may be similar to the satellite sensors 610 a - n , except that the supersensor 612 may be configured to receive and/or store the ping signals from nearby satellite sensors 610 a - n (e.g., in a larger memory than the satellite sensors 610 a - n ), and retransmit the ping signals from nearby satellite sensors 610 a - n along with its own ping signal.
  • the supersensor 612 may therefore act a central node for a dedicated set of satellite sensors 610 a - n , where a supersensor 612 collects and/or processes various parameters and measurements from the satellite sensors 610 a - n .
  • the supersensor 612 may be configured to transmit information through one or more additional supersensors 612 ′ (if necessary).
  • the supersensor 612 and other supersensors 612 ′ in the chain are able transmit information to a receiving point outside the environment (e.g., collection/processing controllers), typically residing on the surface.
  • the satellite sensors 610 a - n may therefore be configured to transmit the ping signals over a relatively short transmission range compared to the supersensor 612 .
  • the power requirements for the satellite sensors 610 a - n may be reduced compared to the supersensor 612 .
  • the reduced power requirements and transmission range of the satellite sensors 610 a - n may allow the wireless communication module 314 , energy harvester module 318 , data storage/signal processing module 316 , and/or memory 320 to be smaller and/or less expensive compared to the supersensor 512 .
  • the reduced size of the satellite sensors 610 a - n compared to the supersensor 612 and/or regular microsensor 10 may allow the satellite sensors 610 a - n to penetrate deeper in the rock formations which is beneficial in the case of fracking.
  • the supersensors 612 are of larger form factor ranging from 8 mm to 50 mm in size compared to the satellite sensor 610 a - n which can be 1-20 mm in size.
  • the supersensor 612 may be 20 mm to 40 mm in size while the satellite sensor 610 a - n may be 2-4 mm in size.
  • the satellite/node sensor system 700 may include one or more (e.g., a plurality of) microsensors 710 a - n in communication with one or more nodes 712 .
  • the nodes 712 may form the backbone in the satellite/node sensor system 700 through which data transmitted by their respective microsensors 710 a - n is collected, processed and transmitted.
  • the microsensors 710 a - n may be configured to generate and transmit ping signals including the sensor data and optionally location information and/or a unique identifier.
  • the fixed nodes and/or collection points may be introduced into the well bore 12 together with, or separate from, the microsensors 10 a - n .
  • the number of fixed nodes and/or collection points may be determined based on the wireless transmission range of the microsensors 10 a - n , the number of microsensors 10 a - n , and/or an estimate or expected distribution/location of the microsensors 10 a - n within the well bore 12 .
  • the nodes 712 may be similar to the satellite sensors 710 a - n , except that the nodes 712 do not include a sensor module. As such, the nodes 712 are configured to receive and/or store the ping signals from nearby microsensors 710 a - n (e.g., in a larger memory than the satellite sensors 710 a - n ), and retransmit the ping signals from nearby microsatellite sensors 710 a - n . The nodes 712 may therefore act a central node for a dedicated set of microsatellite sensors 710 a - n , where a node 712 collects and/or processes various parameters and measurements from the microsatellite sensors 710 a - n .
  • the nodes 712 may be configured to transmit information through one or more additional nodes 712 ′ (if necessary).
  • the nodes 712 and other nodes 712 ′ in the chain are able transmit information to a receiving point outside the environment (e.g., collection/processing controllers), typically residing on the surface.
  • the microsatellite sensors 710 a - n may therefore be configured to transmit the ping signals over a relatively short transmission range compared to the node 712 .
  • the power requirements for the microsatellite sensors 710 a - n may be reduced compared to the node 712 .
  • the reduced power requirements and transmission range of the microsatellite sensors 710 a - n may allow the wireless communication module 314 , energy harvester module 318 , data storage/signal processing module 316 , and/or memory 320 to be smaller and/or less expensive compared to the node 712 .
  • the reduced size of the microsatellite sensors 710 a - n compared to the node 712 and/or regular microsensor 10 may allow the microsatellite sensors 710 a - n to penetrate deeper in the rock formations which is beneficial in the case of fracking. Additionally, the cost of the nodes 712 may be reduced since they do not need to include a sensor module 310 .
  • the system may include a plurality of microsensors 810 a - n that, once activated, may cluster together to form a single larger cluster 812 .
  • the cluster 812 microsensors 810 a - n may aid in keeping the cracks open during and/or post fracking process.
  • the cluster 812 may be achieved through one or more of electrostatic surface charge generation and/or surface coatings 814 .
  • the electrostatic surface charge generation and/or surface coatings may use van der Waals forces that will allow the microsensors 810 a - n to aggregate and/or stick together to form a cluster 812 .
  • a cluster 812 of microsensors 810 a - n that are coupled or attached together can be fragmented into smaller sensors by aligning the surface polarity and making them the same for all sensors, thus creating repelling forces that will fragment the clusters.
  • similar aggregation may be accomplished using a supersensor where simple satellites sensors would adhere by providing a change in the surface polarity to attract and bind the simple satellites sensors.
  • a self-powered microsensor 10 including one aspect of an electrochemical energy harvester module 318 is generally illustrated.
  • the electrochemical energy harvester module 318 may be formed by two dissimilar metals (e.g., copper and aluminum) on an outer surface or skin 910 (e.g., in grooves) of the microsensor 10 . When these metals contact an ionic solution during use, an electrochemical cell is formed, this is capable of supplying sufficient voltage to power the microsensor 10 . Although the metals may eventually corrode, ceasing operation of electrochemical energy harvester module 318 , dissolvable coatings may be used to delay activation of the electrochemical energy harvester module 318 as described above.
  • microsensors consistent with embodiments disclosed herein, provides advantages over other techniques used for tracing such as including radioactive tracer isotopes in the hydrofracturing fluid to determine the injection profile and location of fractures created by hydraulic fracturing. Most of these other techniques are passive, which cannot sense, store, process or transmit the data.
  • the self-powered microsensors provide an advantage by harvesting from the environment to provide energy for a smart sensor system.
  • the microsensors may also be made from 2-D and 1-D nano-materials capable of operating at high temperatures, high pressures, and in corrosive environments.
  • the electronics in these microsensors may be made using high temperature compatible advanced material systems. Accordingly, self-powered microsensors, consistent with embodiments of the present disclosure, are capable of providing the desired measurements while also surviving extremely harsh environments (e.g., high temperature, high pressure, and corrosion).
  • module may refer to software, firmware and/or circuitry configured to perform one or more operations consistent with the present disclosure.
  • Software may be embodied as a software package, code, instructions, instruction sets and/or data recorded on non-transitory computer readable storage mediums.
  • Firmware may be embodied as code, instructions or instruction sets and/or data that are hard-coded (e.g., nonvolatile) in memory devices.
  • Circuitry as used in any embodiment herein, may comprise, for example, singly or in any combination, hardwired circuitry, programmable circuitry such as computer processors comprising one or more individual instruction processing cores, state machine circuitry, software and/or firmware that stores instructions executed by programmable circuitry.
  • the modules may, collectively or individually, be embodied as circuitry that forms a part of one or more devices, as defined previously.
  • the modules described herein may be in the form of logic that is implemented at least in part in hardware to perform various functions consistent with the present disclosure.
  • the present disclosure features a delayed-activation sensor system.
  • the delayed-activation sensor system includes at least one microsensor having at least one sensor module for sensing a condition in an environment, and a dissolvable coating encapsulating at least a portion of the at least one sensor module such that the dissolvable coating prevents the at least one sensor module from sensing the condition in the environment.
  • the dissolvable coating may be dissolvable in a fluid in the environment such that the sensor module is activated after being located in the environment for a period of time.
  • the present disclosure features a self-powered microsensor for sensing a condition in an environment.
  • the self-powered micro-sensor includes at least one energy harvester module to generate electrical power for the microsensor from the environment, and at least one sensor module electrically coupled to the electrochemical energy harvester module.
  • the present disclosure features a method of in-situ monitoring a hydraulic fracturing operation.
  • the method includes injecting a plurality of dissolvable coated self-powered microsensors into a well bore, dissolving of coating on self-powered microsensors in the well bore, activating the self-powered microsensors, and obtaining measurements from each of the self-powered microsensors.

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