In the demanding world of oil and gas exploration, precision and reliability are non-negotiable.
Topside measurements often fall short in deep, deviated, or horizontal wells, making accurate downhole data a critical need.
Interface, a trusted leader in force measurement for the energy industry, has engineered a solution to this long-standing problem: the Interface Pressure Compensated Downhole Load Cell (IPCD). This innovative product provides accurate, real-time force measurement directly at the source, overcoming the limitations of traditional technologies.
What is the problem with traditional "wet" load cells?
For years, the industry has relied on "wet" load cells for downhole force measurement. These systems use a hydraulic compensation method with pistons and seals to counteract the immense pressures found deep underground. However, this approach comes with significant drawbacks:
- High Maintenance and Cost: The moving seals in wet load cells create friction and error, and they require frequent replacement. This leads to high service costs, tool disassembly, and costly downtime.
- Reduced Accuracy: The hydraulic compensation exposes the strain gages to silicon oil, which shortens their lifespan and compromises data accuracy.
- Limited Application: Wet load cells rely on above-ground readings, making them ineffective for horizontal wells, which have become increasingly popular with the rise of fracking.
What is the best solution for accurate downhole data?
The Interface IPCD load cell offers a superior alternative. Interface's proprietary internal compensation method allows the device to actively measure only the axial force, while completely ignoring the effects of high pressure and temperature. This groundbreaking approach provides several key advantages:
- Exceptional Accuracy and Reliability: The IPCD is a Wheatstone bridge, foil-gaged-based solution that is fully compensated for both pressure (up to 20,000 PSI) and temperature (up to 400°F). It delivers world-class linearity and hysteresis, ensuring highly accurate and repeatable data. The design is also incredibly robust, with a 30,000 lbf safe load rating and a 90,000 lbf ultimate load rating.
- Maintenance-Free Design: Unlike wet load cells, the IPCD is a self-contained, completely analogue solution. The internal compensation eliminates the need for a pressure vessel and moving parts, making it a "maintenance-free" solution that reduces long-term costs and downtime.
- Expanded Applications: The IPCD can be used in both vertical and horizontal wells. It's ideal for a wide range of oil and gas applications.
Downhole drilling use cases
Deviated and lateral wells render topside measurements of little value. Successful pump down services require accurate tool string tension readings, downhole, at the source. The IPCD Pressure Compensated Downhole Load Cell is a precise and reliable load cell that Interface has explicitly developed for downhole tension and compression measurements in high-temperature, high-pressure well conditions.
How does a downhill load cell work?
- The IPCD Pressure Compensated Downhole Load Cell is integrated near the top of the tool string.
- During pump down, the IPCD measures the tension between the cable head and the tool string.
- Connected to the customer's instrumentation, actual cable head tension is closely monitored across any variation of temperature or pressure.
Featuring proprietary pressure and temperature compensation, precise tool string force measurements can be monitored in real time through customer instrumentation. The solutions provide control of the pumping forces on the tool string with incredible accuracy. Regulating this process ensured service success without the risk of tool pump off, avoiding a devastating and expensive fishing operation.
How do load cells work in a horizontal well application?
When a pumpdown operation is used for horizontal wells in the oil field, fluid is pumped to push tools down the deviated or horizontal wells. Operations could include plug setting and perforation. Accurate tool string tension readings are required for this downhole procedure. The IPCD Pressure Compensated Downhole Load Cell is a correct and superior load cell over wet or hydraulically compensated load cell options. Featuring proprietary pressure and temperature compensation, offering precise and real-time tool string force measurements. You can learn more about this use case in the Wireline Pump Down Application Note.
How can an IPCD load cell operate in a ruggedised downhole environment?
Each IPCD load cell is individually tested to meet the rigorous demands of the downhole environment, with comprehensive testing for force, creep, pressure, and temperature. While the IPCD is not currently NACE compliant for sour gas applications, custom solutions can be designed to meet specific needs.
By providing a durable, high-performance, and maintenance-free solution, the Interface Pressure Compensated Downhole Load Cell is setting a new standard for force measurement in the oil and gas industry.
Interface leverages experience, engineering design, and production skills to provide standard model solutions. It should be noted that there is still an option to modify the IPCD Load Cell and customise it to adapt to customer hardware.
Interface stands out by offering ruggedised, high-accuracy load cells specifically designed for the oil and gas sector's demanding environments. Interface helps the energy market with force measurement solutions specially developed for harsh conditions, with sensors that can withstand up to 30,000 psi and 500 degrees Fahrenheit.
What oil and gas applications can load cell technology help with?
Downhole and Vertical Drilling
- Dry Load Cell Replacements for Wet Load Cells
- Drill String Weight and Tension Monitoring
- Oil Recovery
- Wellbore Perforation Equipment
- Wireless Drilling Systems and Rig Management
Flow Management
- Monitoring Pipeline Tension
- Pipeline Stress Monitoring
- Mooring and Riser Systems
Wellhead and Production Operations
- Tank and Silo Weighing
- Cementing Tools
- Wireline Tools
- Crane and Lifting Equipment
- Mixing and Separation Systems
- Offshore Equipment
You can also tune into our Ruggedised Solutions Webinar, where we detail the requirements and application use cases.
How do load cells work in harsh environments?
Our moment and temperature compensated LowProfile™ load cells use proprietary alloy strain gages to provide the most accurate readings possible in the harshest environments, such as downhole drilling, wirelines, pipelines, and wind turbines. Interface tests every LowProfile™ load sensor for accuracy and temperature specifications, and moment compensates each unit to minimize sensitivity to extraneous loads. Using eight proprietary strain gages per sensor, our 4mV/V output which exceeds most other load cell performance specifications.
Frequently Asked Questions
Choosing the right technology for downhole force measurement is critical in oil and gas operations. Engineers and operators often ask how pressure compensated load cells compare to traditional wet load cells, whether they can perform in horizontal wells, and what applications they are best suited for. To help, we’ve gathered answers to the most common questions about Interface’s IPCD Pressure Compensated Downhole Load Cell.
What is a downhole load cell?
A downhole load cell measures tension and compression forces directly inside oil and gas wells.
Why are wet load cells unreliable?
Wet load cells rely on seals and oil, which reduce accuracy and increase maintenance.
How does the IPCD load cell work?
The IPCD uses internal pressure and temperature compensation to measure only axial force.
Can load cells be used in horizontal wells?
Yes, IPCD load cells provide accurate tool string force readings in horizontal wells.
What is the pressure rating of the IPCD load cell?
The IPCD is pressure compensated up to 20,000 PSI and temperature tested up to 400°F.
Do IPCD load cells need maintenance?
No, IPCDs are maintenance-free with no seals or moving parts.
Is the IPCD load cell suitable for HPHT environments?
Yes, it is tested for high-pressure, high-temperature drilling conditions.
Is the IPCD load cell NACE compliant?
Not currently, but customised solutions are available for sour gas applications.
What oil and gas applications use load cells?
Load cells are used for drill string monitoring, pump-down operations, perforation, and pipeline tension.
Who supplies IPCD load cells in the UK?
Interface Force Measurements Ltd distributes and supports IPCD load cells in the UK and beyond.
Downhole load cells – find out more
- Product information:
- Application notes – Energy industry:
- Please get in touch for additional information and to look over your use case for pressure compensated downhole load cells and other Interface ruggedised sensor technologies.
Interface Force UK: provider of the world’s most accurate and reliable force measurement sensors and products
Highly regulated, complex, and vital industries rely on Interface Force UK for value, reliability, and accuracy in the full line of products we offer. Interface supplies precision force and torque measurement devices in the UK to ensure quality when product failure is not an option. This is also why we have been a trusted partner in the oil and gas industry since we were founded in 1968. Our solutions are used in every facet of energy production from research and exploration, to monitoring equipment especially our oil and gas energy sensors. Load cells and torque transducers assist oil, gas, wind, coal, solar, and emerging energy companies to fuel the world. When our petroleum customers came to us requesting load cells that could withstand up to 30,000 psi and 500°F, we met the challenge with custom application-specific solutions.
Are Interface Force solutions available outside of the US?
Interface Force Measurements Ltd is the master distributor for Interface load cells in the UK, Ireland, Middle East and North Africa. Interface’s success is due to a global network and partnership with Interface Force Measurements Ltd. We are technical experts on our load cells, torque transducers, sensors, instrumentation and services and can help you with your applications requiring an Interface solution.
