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.

The development work during this quarter was focused in the test of the wireless gauge in a well. The tool was sent to Halliburton for a test. The company indicated that the test well was not available for 4 months and the company was not able to schedule a test of the wireless gauge in its test well. The tool was returned to Tubel Tech's facility in The Woodlands. Tubel Tech is looking for a new test well to deploy the wireless gauge to complete the requirements for the DOE.

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 in 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 …

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) 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. …

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 reducing 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 …

The second quarter of the project was dedicated to convert the conceptual designs for the wireless tool and power generator into mechanical and electrical drawings as well as software code to create the new system. The tasks accomplished during this report period were: (1) Basic mechanical design for the wireless communications system was created and the detailed drawings were started. (2) Basic design for the power generator system was created and the detailed machining drawings were started. The generator design was modified to provide a direct action between the wellbore fluid flow and the piezoelectric stack to generate energy. The new design eliminates the inefficiencies related to picking up outside the tubing wall the pressure fluctuations occurring inside the tubing walls. (3) The new piezoelectric acoustic generator design was created and ordered from the manufacturer. The system will be composed of 40 ceramic wafers electrically connected in parallel and compressed into a single generator assembly. (4) The acoustic two-way communications requirements were also defined and the software and hardware development were started. (5) The electrical hardware development required to transmit information to the surface and to receive commands from the surface was started.

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 conceptual 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 …