Techniques for monitoring downhole data using a downhole sensor

Abstract

A downhole tool may include a casing reading system. A downhole tool may include a processor. A downhole tool may include a hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising receiving spatial data from the casing reading system; and analyzing the spatial data to detect one or more properties associated with a casing of a borehole.

Description

PRIORITY

[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 710,808, filed Oct. 23, 2024, and titled TECHNIQUES FOR MONITORING DOWNHOLE DATA USING A DOWNHOLE SENSOR, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure generally relates to techniques for monitoring wellbore data using a downhole sensor. This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as an admission of any kind.

[0003] Acoustic and other recording devices have been used to measure, sense, and record dimensions of downhole wellbore components, including casing, cement, and perforation hole sizes. For casing, such information from these devices can be used to determine casing ovalities, assess thread damage, and / or casing wall loss. Additionally, such information can be used to record imperfections and / or marks in the wall of the casing, such as a slip mark from a fracturing plug. Powerful readers can penetrate through the casing and measure dimensions of materials on the outside of the casing, such as cement. The information from these readers can then be used to assess the integrity and presence of cement around the casing.

[0004] In order to measure perforating hole size for a particular stage, measurement is typically performed prior to pumping a stimulation into the stage and after pumping the stimulation into the stage. Measuring perforating hole size is typically performed to verify charge performance as well as to monitor cluster erosion efficiency. However, such measurement runs are performed separately from a plug and perf bottom hole assembly run and can be quite costly. Accordingly, improvements in gathering data on wellbore dimensions and conditions are highly desirable.SUMMARY

[0005] A summary of certain embodiments described herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure.

[0006] Certain embodiments of the present disclosure are directed to techniques for monitoring wellbore data using a downhole sensor. In one embodiment, a wellbore reader may be incorporated into a bottomhole assembly (BHA) to gather data associated with wellbore dimensions and conditions during a wellbore operation. For example, the wellbore operation may include a plug and perf operation. Such wellbore dimensions and conditions may include perforation size.

[0007] After the wellbore reader has gathered the data, it may be stored locally and retrieved on surface, or the data may be transmitted to the surface for analysis. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing. Additional parameters this tool will capture are velocities, orientation, and inclination of the tool both when RIH and during perforating.

[0008] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0009] Various refinements of the features noted above may be undertaken in relation to various aspects of the present disclosure. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. The brief summary presented above is intended to familiarize the reader with certain aspects and contexts of embodiments of the present disclosure without limitation to the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, non-schematic drawings should be considered as being to scale for some embodiments of the present disclosure, but not to scale for other embodiments contemplated herein. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0011] FIG. 1 illustrates a drilling system and downhole environment, according to some embodiments of the present disclosure.

[0012] FIGS. 2-1 and 2-2 illustrate a downhole environment in which a tool string creates and measures a perforation in a casing, according to some embodiments of the present disclosure.

[0013] FIG. 3 is a perspective view of a measuring sub including an optical casing reader, according to some embodiments of the present disclosure.

[0014] FIG. 4 is a side cross-sectional view of a measuring sub including an optical casing reader, according to some embodiments of the present disclosure.

[0015] FIG. 5 is a perspective view of a measuring sub including an induction casing reader, according to some embodiments of the present disclosure.

[0016] FIG. 6 is a side cross-sectional view of a measuring sub including an induction casing reader, according to some embodiments of the present disclosure.

[0017] FIG. 7 is a flowchart illustrating a method of measuring a casing property in a downhole environment, according to some embodiments of the present disclosure.

[0018] FIG. 8 is a flowchart illustrating a method of measuring a perforation property in a downhole environment, according to some embodiments of the present disclosure.DETAILED DESCRIPTION

[0019] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0020] When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0021] As used herein, the terms “connect,”“connection,”“connected,”“in connection with,” and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element.” Further, the terms “couple,”“coupling,”“coupled,”“coupled together,” and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements.” As used herein, the terms “up” and “down,”“uphole” and “downhole”, “upper” and “lower,”“top” and “bottom,” and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top (e.g., uphole or upper) point and the total depth along the drilling axis being the lowest (e.g., downhole or lower) point, whether the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0022] In addition, as used herein, the terms “real time”, “real-time”, or “substantially real time” may be used interchangeably and are intended to described operations (e.g., computing operations) that are performed without any human-perceivable interruption between operations. For example, as used herein, data relating to the systems described herein may be collected, transmitted, and / or used in control computations in “substantially real time” such that data readings, data transfers, and / or data processing steps occur once every second, once every 0.1 second, once every 0.01 second, or even more frequent, during operations of the systems (e.g., while the systems are operating). In addition, as used herein, the terms “automatic” and “automated” are intended to describe operations that are performed or caused to be performed, for example, by a processing system (i.e., solely by the processing system, without human intervention). In addition, as used herein, the term “approximately equal to” may be used to mean values that are relatively close to each other (e.g., within 5%, within 2%, within 1%, within 0.5%, or even closer, of each other).

[0023] As mentioned above, certain embodiments of the present disclosure are directed to techniques for monitoring wellbore data using a downhole sensor. In one embodiment, a wellbore or casing reader may be incorporated into a bottomhole assembly (BHA) to gather data associated with wellbore dimensions and conditions during a wellbore operation. For example, the wellbore operation may include a plug and perforation (“plug and perf”) operation. Such wellbore dimensions and conditions may include perforation size, perforation shape, perforation aspect ratio, perforation depth, etc.

[0024] After the wellbore or casing reader has gathered the spatial data, the spatial data may be transmitted to the surface for analysis. The spatial data may be transmitted to the surface by wired communication, wireless communication, or by storage of the spatial data on a local hardware storage device in the downhole environment for subsequently tripping of the tool to the surface. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing.

[0025] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0026] In certain embodiments, a measuring sub (e.g., a wellbore or casing reader) is provided in a tool string. In one embodiment, the measuring sub may be provided between a perforation gun section and a firing head of the tool string. However, in other embodiments, the measuring sub may be disposed in any other suitable position in the tool string. In certain embodiments, the measuring sub can run off battery power and / or have memory on board. In other embodiments, the measuring sub can receive power through a wired connection, such as other components of the tool string, wireline, coiled tubing, or any other suitable source. In certain embodiments, it may benefit to position the measuring sub in the tool string as low as possible in order to obtain the most and / or most valuable types of information. For instance, the position of the measuring sub may be conveyed to the lowest depth of a bottom hole assembly of the tool string.

[0027] FIG. 1 illustrates an embodiment of a drilling system and downhole environment. FIG. 1 shows one example of a drilling system 100 for drilling an earth formation 101 to form a borehole 102. The drilling system 100 includes a drill rig 103 used to turn a drilling assembly 104 which extends downward into the borehole 102. The drilling assembly 104 may include a drill string 105 and a bottomhole assembly (BHA) 106 attached to the downhole end of the drill string 105. Where the drilling system 100 is used for drilling formation, a drill bit 110 can be included at the downhole end of the BHA 106.

[0028] The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and can transmit rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 may further include additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid 111 is pumped from the surface. The drilling fluid 111 discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, for lifting cuttings out of the borehole 102 as it is being drilled, and for preventing the collapse of the borehole 102. The drilling fluid 111 carries drill solids including drill fines, drill cuttings, and other swarf from the borehole 102 to the surface. The drill solids can include components from the earth formation 101, the drilling assembly 104 itself, from other man-made components (e.g., plugs, lost tools / components, etc.), or combinations thereof.

[0029] The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and / or the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (MWD) tools, logging-while-drilling (LWD) tools, downhole motors, underreamers, directional steering tools, section mills, hydraulic disconnects, jars, vibration dampening tools, other components, or combinations of the foregoing.

[0030] In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, safety valves, centrifuges, shaker tables, and rheometers). Additional components included in the drilling system 100 may be considered a part of the surface system (e.g., drill rig 103, drilling assembly 104, drill string 105, or a part of the BHA 106, depending on their locations and / or use in the drilling system 100).

[0031] The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits, roller cone bits, impregnated bits, or coring bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing 107 lining the borehole 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the borehole 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface by the drilling fluid 111 or may be allowed to fall downhole. The conditions of the equipment of the drilling system 100, the formation 101, the borehole 102, the drilling fluid 111, or other part of the wellsite can change during operations.

[0032] After construction of the wellbore, the casing 107 may be installed, perforated, or modified during production. In some embodiments, a wireline (or other conveyance system, such as coiled tube) tool string may be delivered into the wellbore to measure or monitor the casing or wellbore conditions, as well as perforate or otherwise modify the casing. In some embodiments according to the present disclosure, a tool string includes measuring sub configured to measure at least one casing property of the casing and store data associated with the casing property on a hardware storage device local to the tool string. In some embodiments according to the present disclosure, a tool string includes both a perforation tool and a measuring sub configured to measure at least one perforation property of a resulting perforation, such that the perforation can be made in the casing and the perforation property can be measured in a single trip of the tool string downhole (such as in a single Plug-and-Perf trip). In at least one embodiment, the perforation tool is located in the tool string uphole from the measuring sub, such that the measuring sub is configured to measure a perforation property as the tool string is moved uphole after each firing of a perforation tool. In other words, the tool string may be moved continuously or sequentially uphole to each perforation location within a target zone, with the measuring sub passing by the previous perforation location (and measuring the perforations therein) during transit to the next perforation location.

[0033] In some embodiments, a measuring sub includes an optical measurement system. For example, the optical measurement system includes an optical sensor array that can detect casing dimensions using camera and visual analysis. In some embodiments, a measuring sub includes an induction measurement system. For example, the induction measurement system includes an induction sensor array that can detect casing dimensions and / or material using electromagnetic analysis.

[0034] FIG. 2-1 and FIG. 2-2 illustrate an embodiment of a tool string 212 that is tripped into a formation 201 through a borehole 202 having a casing 207. In some embodiments, the tool string 212 includes a plug tool 214 that may be positioned in a borehole 202. The plug tool 214 may be deployed to contact the casing 207 and create a fluid seal between the plug tool 214 and the casing 207 to isolate a portion of the borehole 202. In some embodiments, the plug tool 214 is deployed in the casing 207 before perforation of the casing 207 with a perforation tool 216 of the tool string 212. In some embodiments, the tool string 212 includes at least one perforation tool 216. In some embodiments, the tool string 212 includes a plurality of perforation tools 216 in series in the axial direction of the tool string 212.

[0035] The perforation tool(s) 216 is configured to create perforations 218 in the casing 207 and / or into the formation 201 using one or more perforating mechanisms, such as guns 217. For example, the guns 217 may be single-use mechanisms with a single charge loaded in each gun 217. In some embodiments, a perforation tool 216 has a plurality of perforating mechanisms, and the tool string 212 has a plurality of perforation tools 216 that may each be used once in a single trip of the tool string 212 into the borehole 202. In some embodiments, the perforation tool 216 is configured to provide multiple perforations per each perforating mechanism.

[0036] In some embodiments, the perforations 218 provide fluid communication between the borehole 202 and the formation 201. For example, the formation 201 includes a formation fluid, such as water, oil, gas, or a combination thereof, that may flow into the wellbore during production operations. In some examples, a fluid is provided into and / or through the borehole 202 to enter the formation 201, such as a drilling fluid and / or a proppant carrier fluid to provide a proppant into the formation 201 to support the formation 201 during production.

[0037] In some embodiments, the tool string 212 includes a measuring sub 220 configured to measure one or more properties of the casing 207 and / or one or more properties of the perforation(s) 218. In some embodiments, the measuring sub 220 is configured to measure a casing property, such as casing ovality of an inner surface of the casing 207, aspect ratio of the inner surface of the casing 207, casing thickness, casing roughness, or other casing properties. In some embodiments, the measuring sub 220 is configured to measure a perforation property, such as perforation ovality, perforation diameter, perforation sharpness, perforation depth (through the casing 207 and / or the formation 201) or other perforation properties. In some embodiments, the measuring sub 220 is configured to additionally measure at least one property of the casing at the location of the perforation, such as deformation, curvature, cracking, or other properties of the interface between the casing and the perforation. The perforation tool(s) 216 is located in the uphole direction 222 of the borehole 202 relative to the measuring sub 220.

[0038] Referring now to FIG. 2-2, the tool string 212 may be moved in an uphole direction 222 of the borehole 202 after the perforation tool 216 perforates the casing 207. In some embodiments, the measuring sub 220 is moved in the uphole direction 222 until the measuring sub 220 is axially aligned in the borehole 202 with the perforation(s) 218 in the casing 207. In some embodiments, the measuring sub 220 is configured to measure at least one casing property and / or at least one perforation property while moving relative to the casing 207 and / or formation 201. In some examples, the measuring sub 220 measures the casing 207 and / or perforation(s) 218 substantially continuous while moving to assemble an image of the casing and / or perforation(s) 218. In some embodiments, the measuring sub 220 is configured to measure at least one casing property and / or at least one perforation property while stationary relative to the casing 207 and / or formation 201. In some examples, the measuring sub 220 (and tool string 212) may be stopped proximate to the casing 207 and / or perforation(s) 218 to measure the casing and / or perforation property via a camera that images the inner surface of the casing 207 and / or the perforation(s) 218.

[0039] FIG. 3 through FIG. 6 illustrate embodiments of measuring subs that may be tripped into the borehole in a tool string including a perforation tool(s) that may measure at least one perforation property in the same trip as the perforation(s) is created in the casing. In some embodiments, the measuring sub includes a casing reader configured to measure casing properties of a casing and / or perforation properties of perforation(s) therein. FIG. 3 is a perspective view of an embodiment of a measuring sub 320 including an optical casing reader.

[0040] In some embodiments, the measuring sub 320 includes a housing 324 (transparent in FIG. 3). In some embodiments, the housing 324 is transparent to light in a wavelength detectable by an optical sensor 326 of the measuring sub 320. In some embodiments, the housing 324 is made of the transparent material. In some embodiments, the housing 324 includes a window of transparent material that is proximate to the optical sensor 326. The optical sensor collects spatial data of the surrounding environment of the measuring sub. In some embodiments, the spatial data is two-dimensional data. In some embodiments, the spatial data is three-dimensional data. In some embodiments, the optical sensor 326 is or includes a visible light camera. In some embodiments, the optical sensor 326 is or includes an invisible wavelength light camera, such as an infrared light camera or an ultraviolet light camera. In some embodiments, the optical sensor 326 is or includes a laser sensor. In some embodiments, the optical sensor 326 is or includes a depth camera, such as a time-of-flight camera or a stereographic camera configured to determine depth information while imaging an object in the field of view of the camera.

[0041] In some embodiments, the optical sensor 326 further includes an illumination source. In some embodiments, an illumination source is located in the measuring sub 320 with the optical sensor 326 such that the optical sensor 326 can detect the reflected light from the illumination source.

[0042] In some embodiments, the optical sensor 326 is one of a plurality of optical sensors 326 of the measuring sub 320. In some embodiments, the plurality of optical sensors 326 is arranged in an array with overlapping field-of-views to measure the casing property and / or perforation property. In some embodiments, the plurality of optical sensors 326 is arranged circumferentially around the measuring sub 320 to capture an image or other optical information in a full circumference around the measuring sub 320 and a full inner surface of the casing of the borehole.

[0043] In some embodiments, the plurality of optical sensors 326 is arranged with at least a first optical sensor and a second optical sensor displaced in an axial direction with the first optical sensor located in a downhole direction relative to the second optical sensor. For example, the first optical sensor may be one of a first set of circumferential optical sensors 326, and the second optical sensor may be one of a second set of circumferential optional sensors 326 that is positioned axially displaced from the first set. In some embodiments, at least one optical sensor 326 is rotationally aligned with the perforation tool outlets, such as the guns described in relation to FIG. 2-1, such that the optical sensor is rotationally aligned with a perforation created thereby upon axial movement of the tool string in the uphole direction. In some embodiments, a plurality of optical sensors 326 are rotationally aligned with a plurality of perforation tool outlets, such as each oriented at 90° spacing around the rotational axis of the tool string or 120° spacing around the rotational axis.

[0044] As described herein, a measuring sub according to the present disclosure is configured to measure and record a casing property and / or a perforation property after perforation of the casing with a perforation tool in a single trip of the tool string into the borehole without tripping the perforation tool out of the borehole. In some embodiments, the measuring sub 320 includes an onboard power supply, such as a battery 328, that allows the measuring sub to record the measurement(s) to a local hardware storage device 330 by a processor 331. In some embodiments, the processor is any microprocessor capable of data communication with the optical sensor(s) 326 to receive the optical information and the hardware storage device 330 to execute instructions stored thereon. The processor 331 may then store measurements on the hardware storage device 330. In some embodiments, the battery 328 or other power supply is configured to provide electrical power at least to the optical sensor(s) 326 and / or hardware storage device 330.

[0045] In some embodiments, the hardware storage device(s) 330 is a non-transient storage device including any of RAM, ROM, EEPROM, CD-ROM or other optical disk storage (such as CDs, DVDs, etc.), magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.

[0046] In some embodiments, the processor(s) 331 is a central processing unit (CPU) that performs general computing tasks for the measuring sub 320. In some embodiments, the processor(s) 331 is or is part of a system on chip (SoC) that is dedicated to controlling or communicating with one or more subsystems of the measuring sub 320. In some embodiments, the processor 331 is in data communication with the hardware storage device 330 to execute instructions stored thereon that cause the processor 331 to perform any of the methods or a portion of any of the methods described herein.

[0047] FIG. 4 is a side cross-sectional view of an embodiment of a measuring sub 420 including an optical casing reader. In some embodiments, the measuring sub 420 includes a body 432 that supports a housing 424. In some embodiments, the housing 424 is positioned radially outside of and overlapping at least one optical sensor 426. In some embodiments, the housing 424 is positioned radially outside of and overlapping the battery 428, hardware storage device 430, and / or processor 431.

[0048] FIG. 5 is a perspective view of an embodiment of a measuring sub 520 including an induction casing reader. In some embodiments, the measuring sub 520 includes a housing 524 (transparent in FIG. 5). In some embodiments, the housing 524 is transparent to electromagnetic fields detectable by an induction sensor 534 and / or produced by an induction coil 536 of the measuring sub 520. In some embodiments, the housing 524 is made of a magnetically transparent material, such as a polymer or a non-magnetic metal or metal alloy. In some embodiments, the housing 524 includes a window of magnetically transparent material that is proximate to the induction sensor 534 and / or induction coil 536. In some embodiments, the housing 524 includes one or more apertures therein such that the induction sensor 534 and / or induction coil 536 is exposed to the borehole fluid or other contents of the borehole. In such examples, the housing 524 may be or include a ferromagnetic material without substantially impacting the magnetic field applied by the induction coil(s) 536 to the casing.

[0049] In some embodiments, the induction coil 536 further includes a magnetic field source. For example, the induction coil 536 may include an electromagnetic coil that is selectively energized to produce a magnetic field emanating from the measuring sub 520 (e.g., through the housing 524) that induces a current in the casing. In some embodiments, the magnetic field source includes a permanent magnetic that induces a current as the permanent magnet moves past the casing. In some embodiments, the magnetic field source includes both a permanent magnet and an electromagnet. In some examples, the current may be induced as an eddy current in the casing (such as a steel casing or other ferromagnetic casing) that produces an induced magnetic field from the casing. The induction sensor 534 may then detect the induced magnetic field from the casing. Based at least partially on the detected strength of the induced magnetic field, the induction sensor 534 and / or a processor 531 in data communication with the induction sensor 534 may determine a distance from the induction sensor 534 to the casing, a thickness of the casing, a casing material, a void (e.g., a perforation) in the casing, and other casing properties. In some embodiments, an induction coil 536 is located in the measuring sub 520 with the induction sensor 534 such that the induction sensor 534 can detect an induced magnetic field from the casing induced by the induction coil 536.

[0050] The induction sensor 534 collects spatial data of the surrounding environment of the measuring sub. In some embodiments, the spatial data is two-dimensional data. In some embodiments, the spatial data is three-dimensional data. In some embodiments, the induction sensor 534 is one of a plurality of induction sensors 534 of the measuring sub 520. In some embodiments, the plurality of induction sensors 534 is arranged in an array with overlapping field-of-views to measure the casing property and / or perforation property. In some embodiments, the plurality of induction sensors 534 is arranged circumferentially around the measuring sub 520 to capture an induction image (such as a matrix of induction measurements at various locations) or other induction information in a full circumference around the measuring sub 520 and a full inner surface of the casing of the borehole.

[0051] In some embodiments, the plurality of induction sensors 534 is arranged with at least a first induction sensor and a second induction sensor displaced in an axial direction with the first induction sensor located in a downhole direction relative to the second induction sensor. For example, the first induction sensor may be one of a first set of circumferential induction sensors 534, and the second induction sensor may be one of a second set of circumferential induction sensors 534 that is positioned axially displaced from the first set. In some embodiments, at least one induction sensor 534 is rotationally aligned with the perforation tool outlets, such as the guns described in relation to FIG. 2-1, such that the induction sensor is rotationally aligned with a perforation created thereby upon axial movement of the tool string in the uphole direction. In some embodiments, a plurality of induction sensors 534 are rotationally aligned with a plurality of perforation tool outlets, such as each oriented at 90° spacing around the rotational axis of the tool string or 120° spacing around the rotational axis.

[0052] As described herein, a measuring sub according to the present disclosure is configured to measure and record a casing property and / or a perforation property after perforation of the casing with a perforation tool in a single trip of the tool string into the borehole without tripping the perforation tool out of the borehole. In some embodiments, the measuring sub 520 includes an onboard power supply, such as a battery 528, that allows the measuring sub to record the measurement(s) to a local hardware storage device 530 by a processor 531. In some embodiments, the processor is any microprocessor capable of data communication with the optical sensor(s) 526 to receive the optical information and the hardware storage device 530 to execute instructions stored thereon. The processor 531 may then store measurements on the hardware storage device 530. In some embodiments, the battery 528 or other power supply is configured to provide electrical power at least to the induction sensors 534, the induction coils 536 and / or hardware storage device 530.

[0053] In some embodiments, the hardware storage device(s) 530 is a non-transient storage device including any of RAM, ROM, EEPROM, CD-ROM or other optical disk storage (such as CDs, DVDs, etc.), magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.

[0054] In some embodiments, the processor(s) 531 is a central processing unit (CPU) that performs general computing tasks for the measuring sub 520. In some embodiments, the processor(s) 531 is or is part of a system on chip (SoC) that is dedicated to controlling or communicating with one or more subsystems of the measuring sub 520. In some embodiments, the processor 531 is in data communication with the hardware storage device 530 to execute instructions stored thereon that cause the processor 531 to perform any of the methods or a portion of any of the methods described herein.

[0055] By using an array of induction coils 536, induction can be put into the casing and while traveling the induction sensors 534 that are in an axial row can sense how fast the tool string is moving based on sensing an induction decay rate. For example, an induced current will decay when the inducing magnetic field (e.g., that of the induction coil 536) is removed. In some embodiments, the inducing magnetic field is removed by displacing the induction coil(s) 536 axially away from the region of the casing with the induced current. In some embodiments, the inducing magnetic field is removed by deactivating the induction coil 536, such as de-energizing an electromagnetic thereof.

[0056] The strength of the measured induced magnetic field and the induction decay rate of the induced magnetic field is, in some embodiments, used to sense casing dimensions: diameters, ovalities, thicknesses, etc. A thin casing material may saturate and produce an induced magnetic field of limited strength. A measured strength of a magnetic field decreases exponentially relative to a distance from the source (i.e., the casing), allowing a determination of a distance to the casing (e.g., diameter and / or ovalities when measured in a plurality of directions from the measuring sub).

[0057] In some embodiments, the induction coils 536 produce a magnetic field directed at a portion of the casing including a perforation. No electrical current is inducing in the perforation, and, therefore, no induced magnetic field is detected by the induction sensors 534. Induction sensors 534 that are axially in line or near other sensors will be able to detect this lack of induction in the casing, and by using the speed of the measuring sub relative to the casing (in an axial direction, a rotational direction, or both) the induction sensors 534 and processor 531 detect an approximate perforation size. In some embodiments, the array of induction sensors 534 measures the induced magnetic field and / or induction decay rate at a plurality of locations while stationary or substantially stationary relative to the casing. The relative strength of the induced magnetic field and / or induction decay rate at each location in the array may allow the processor to reconstruct an image of the casing at that location in the borehole.

[0058] FIG. 6 is a side cross-sectional view of an embodiment of a measuring sub 620 including an induction casing reader. In some embodiments, the measuring sub 620 includes a body 632 that supports a housing 624. In some embodiments, the housing 624 is positioned radially outside of and overlapping at least one induction sensor 634 and / or induction coil 636. In some embodiments, the housing 624 is positioned radially outside of and overlapping the battery 628, hardware storage device 630, and / or processor 631.

[0059] In some embodiments, a circumferential set of induction sensors 634 and / or induction coils 636 includes at least one induction sensor 634 and one induction coil 636. In some embodiments, a circumferential set includes a plurality of induction sensors 634 or a plurality of induction coils 636, with a second set positioned axially displaced in the body 632. As described in relation to FIG. 5, in some embodiments, the plurality of induction sensors 634 and / or the plurality of induction coils 636 are positioned in the body 632 without a housing 624 covering the plurality of induction sensors 634 and / or the plurality of induction coils 636. In some embodiments, the plurality of induction sensors 634 and / or the plurality of induction coils 636 are therefore configured to provide and / or detect magnetic fields without interference caused by the housing.

[0060] In some embodiments, a measuring sub according to the present disclosure includes a sonar sensor that uses directional acoustic waves to measure distances to the casing and supplement the spatial data from the optical sensor(s) described in relation to FIGS. 3 and 4 and / or the spatial data from the induction sensor(s) described in relation to FIGS. 5 and 6.

[0061] FIG. 7 is a flowchart illustrating an embodiment of a method 738 of measuring a casing property in a downhole environment. In some embodiments, the method 738 includes providing a downhole sensor incorporated into a tool string at 740. For example, the downhole sensor may be any of the measuring subs, optical sensors, induction sensors, or combinations thereof described herein. In some embodiments, the tool string includes a measuring sub with a processor, hardware storage device, and power supply within the measuring sub to allow operation of the measuring sub independently of power or data communication with other components. In some embodiments, the tool string includes one or more perforation tools uphole of the measuring sub. In some embodiments, the tool string includes a plug tool downhole of the measuring sub. In some embodiments, the tool string includes at least one optical sensor and / or illumination source. In some embodiments, the tool string includes at least one induction sensor and / or induction coil. In some embodiments, the tool string includes both at least one optical sensor and / or illumination source and at least one induction sensor and / or induction coil. For example, a tool string may include at least one optical sensor, at least one illumination source, at least one induction sensor, and at least one induction coil. Such systems may allow additional information or redundancy for measurement of casing and / or perforation properties. For example, some casing materials may not be electrically conductive to produce an induced magnetic field, and the optical sensors may provide information in those regions of the casing. In some examples, a borehole fluid present in the borehole may limit and / or prevent the use of optical measurements of the casing.

[0062] The method 738, in some embodiments, includes positioning the tool string in a downhole environment of a borehole at 742. In some embodiments, positioning the tool string may include moving the tool string in an axial direction of the borehole. For example, positioning the tool string may include moving the tool string axially downhole (which may include horizontal movement of the tool string). In some examples, positioning the tool string may include moving the tool string uphole. In some embodiments, positioning the tool string may include rotation of the tool string in the borehole.

[0063] In some embodiments, positioning the tool string may include moving the tool string via a wireline conveyance mechanism in the borehole. In some embodiments, positioning the tool string may include moving the tool string via a coiled tubing conveyance mechanism in the borehole. In some embodiments, positioning the tool string may include moving the tool string via a drill pipe or other substantially rigid conveyance mechanism in the borehole.

[0064] The method 738 further includes, in some embodiments, determining one or more casing properties of a casing using the downhole sensor at 744. As described herein, determining one or more casing properties of a casing using the downhole sensor may include optical and / or induction measurements. In some embodiments, spatial data including optical measurements is collected by an optical sensor or array of optical sensors, such as described in relation to FIG. 3 and FIG. 4. For example, the optical sensor may be a visible light sensor, an infrared sensor, an ultraviolet sensor, other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0065] In some embodiments, the optical sensor detects light reflected by the casing or other features of the borehole from an illumination source of the measuring sub and / or tool string. For example, the illumination source(s) may be located on the measuring sub and positioned within an array of optical sensors. In some examples, the illumination source(s) may be located adjacent to and / or integrated with an optical sensor. In some embodiments, the illumination source is a visible light source, an infrared source, an ultraviolet source, a source of other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0066] In some embodiments, the optical sensor(s) is a depth camera. For example, the optical sensor(s) and illumination source may be a time-of-flight camera. In some examples, the optical sensors have overlapping fields-of-view and may produce depth measurements by stereoscopic comparison of overlapping features in the overlapping fields-of-view.

[0067] In some embodiments, spatial data including induction measurements is collected by an induction sensor or array of induction sensors, such as described in relation to FIG. 5 and FIG. 6. For example, the induction sensor(s) may measure a strength of an induced magnetic field from an electrically conductive casing, a direction of the induced magnetic field, a decay rate of the induced magnetic field, or other properties of a magnetic field of the casing.

[0068] In some embodiments, an array of induction sensors may allow the measurement of the induced magnetic field relative to an induction coil that induces a current in the electrically-conductive casing to produce the induced magnetic field. In some embodiments, the array of induction coils is interspersed with the induction sensors. In some embodiments, the array of induction coils is axially spaced relative to circumferential sets of the induction sensors.

[0069] Based on the measured direction and strength of the magnetic field, and the changes of such over time, the induction sensors and / or processor connected thereto determines one or more casing properties, such as casing material, casing thickness, casing diameter, casing ovality, etc. The method 738 further includes, in some embodiments, recording the one or more casing properties locally in the tool string at 746. For example, the one or more casing properties (determined by the optical sensor, induction sensor, processor, or combinations thereof) may be recorded locally on the tool string on a hardware storage device thereof. In some embodiments, the data stored on the hardware storage device is subsequently retrieved at the surface of the borehole and / or the data is transmitted to the surface from the tool string for analysis.

[0070] FIG. 8 is a flowchart illustrating an embodiment of a method 848 of measuring a perforation property in a downhole environment. In some embodiments, the method includes providing a downhole sensor and perforation tool incorporated into a tool string at 850. The tool string may include a downhole sensor, such as described in relation to FIG. 7, and a perforation tool with one or more perforating mechanisms, such as described in relation to FIG. 2-1 and FIG. 2-2. In some embodiments, the downhole sensor is configured to measure the perforation created by the perforating tool in a single trip into the borehole without removing the tool string.

[0071] The method 848 includes, in some embodiments, positioning the tool string in a downhole environment of a borehole at 842. In some embodiments, positioning the tool string in a downhole environment is similar to that described in relation to FIG. 7. In some embodiments, positioning the tool string in the downhole environment includes positioning the perforation tool at a target location or zone within the borehole. In some examples, the tool string may be located at a target location for the perforation tool and subsequently moved to measure the perforation with the downhole sensor.

[0072] In some embodiments, the method 848 further includes perforating the casing with the perforation tool at 852. As described in relation to FIG. 2-1, in some embodiments, perforating the casing includes creating perforations through the casing uphole of the downhole sensor. In some embodiments, the perforation tool includes a plurality of perforating guns that produce a plurality of perforations through the casing at an axial position in the borehole. Upon creation of the perforations, the downhole sensor allows measurement of one or more perforation properties to evaluate the success of the perforation creation without tripping the perforation tool out of the borehole. In some embodiments, a series of perforation tools allow the perforation of the borehole casing in a plurality of axial locations.

[0073] In some embodiments, perforating the casing with the perforation tool at 852 is performed after measuring at least one previously existing perforation in the casing. For example, the measuring sub may collect spatial data and / or measure at least one perforation property of a perforation prior to perforating the casing with the perforation tool. In some embodiments, the previously formed perforation is formed earlier in the same trip of the tool string in the downhole environment. In some embodiments, the previously formed perforation is formed in a separate and previous trip of the tool string or a different tool string in the downhole environment.

[0074] The method 848 further includes determining one or more casing properties of a casing using the downhole sensor at 844. In some embodiments, determining one or more casing properties is similar to that described in relation to FIG. 7. The method 848 further includes recording the one or more casing properties locally in the tool string at 846. In some embodiments, recording the one or more casing properties is similar to that described in relation to FIG. 7.

[0075] In some embodiments, the method 848 includes determining one or more perforation properties of a perforation of the casing using the downhole sensor at 854 and recording the one or more perforation properties locally in the tool string at 856. The perforation properties may include any of a perforation area, perforation depth, perforation aspect ratio or ovality, perforation edge shape, perforation location, perforation orientation, or other perforation properties. As described herein, determining one or more perforation properties of a casing using the downhole sensor may include optical and / or induction measurements. In some embodiments, optical measurements are collected by an optical sensor or array of optical sensors, such as described in relation to FIG. 3 and FIG. 4. For example, the optical sensor may be a visible light sensor, an infrared sensor, an ultraviolet sensor, other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0076] In some embodiments, the optical sensor detects light reflected by the perforation edges or other features of the borehole from an illumination source of the measuring sub and / or tool string. For example, the illumination source(s) may be located on the measuring sub and positioned within an array of optical sensors. In some examples, the illumination source(s) may be located adjacent to and / or integrated with an optical sensor. In some embodiments, the illumination source is a visible light source, an infrared source, an ultraviolet source, a source of other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0077] In some embodiments, the optical sensor(s) is a depth camera. For example, the optical sensor(s) and illumination source may be a time-of-flight camera. In some examples, the optical sensors have overlapping fields-of-view and may produce depth measurements by stereoscopic comparison of overlapping features in the overlapping fields-of-view.

[0078] In some embodiments, induction measurements are collected by an induction sensor or array of induction sensors, such as described in relation to FIG. 5 and FIG. 6. For example, the induction sensor(s) may measure a strength of an induced magnetic field from an electrically conductive casing, a direction of the induced magnetic field, a decay rate of the induced magnetic field, or other properties of a magnetic field of the casing. For example, a region of the casing that exhibits less or no induced magnetic field relative to a surrounding region of the casing indicates a perforation where the casing material has been removed or displacement.

[0079] In some embodiments, an array of induction sensors may allow the measurement of the induced magnetic field relative to an induction coil that induces a current in the electrically-conductive casing to produce the induced magnetic field. In some embodiments, the array of induction coils is interspersed with the induction sensors. In some embodiments, the array of induction coils is axially spaced relative to circumferential sets of the induction sensors.

[0080] After the wellbore reader has gathered the data, it may be stored locally and retrieved on surface, or the data may be transmitted to the surface for analysis. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing. In some embodiments, the optical and / or induction sensors measure velocities, orientation, and inclination of the tool string when running in hole and during perforating the casing.

[0081] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0082] Although certain embodiments of the present disclosure are described with respect to measuring data associated with a perforation operation, it should be understood that such embodiments are not limited to such operations. Indeed, embodiments of the present disclosure may be applied to gathering and analyzing data associated with any type of wellbore operation using a downhole sensor as described herein. In certain embodiments, the measuring sub (e.g., a wellbore reader) may include an acoustic sensor, or any other suitable type of sensor.

[0083] The present disclosure contemplates devices, systems, and methods for downhole measurements according to at least the following clauses:

[0084] Clause 1. A measuring sub of a tool string, comprising: a casing reading system; a processor; and a hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising: receiving spatial data from the casing reading system; and analyzing the spatial data to detect one or more properties associated with a casing of a borehole.

[0085] Clause 2. The measuring sub of clause 1, wherein the casing reading system includes an optical array.

[0086] Clause 3. The measuring sub of clause 1, wherein the casing reading system includes an induction sensor array.

[0087] Clause 4. The measuring sub of clause 1, wherein the spatial data includes visual data of the casing.

[0088] Clause 5. The measuring sub of clause 1, wherein the spatial data includes material data of the casing.

[0089] Clause 6. The measuring sub of clause 1, wherein the spatial data includes an aspect ratio of the casing.

[0090] Clause 7. The measuring sub of clause 1, wherein the spatial data includes perforation data of the casing.

[0091] Clause 8. The measuring sub of clause 1, wherein the spatial data includes thickness data of the casing.

[0092] Clause 9. The measuring sub of clause 1, wherein the spatial data includes a plurality of measurements associated with overlapping axial positions in the borehole.

[0093] Clause 10. The measuring sub of clause 1, wherein the instructions further cause the processor to store the one or more properties associated with the casing locally to the measuring sub.

[0094] Clause 11. The measuring sub of clause 10, wherein the one or more properties associated with the casing are stored on the hardware storage device.

[0095] Clause 12. A method of measuring a casing property, the method comprising: providing a downhole sensor incorporated into a tool string; positioning the tool string in a downhole environment of a borehole; determining one or more casing properties of a casing using the downhole sensor; and recording the one or more casing properties locally in the tool string.

[0096] Clause 13. The method of clause 12, wherein the tool string further includes a perforation tool, and further comprising: perforating the casing with the perforation tool; determining one or more perforation properties of a perforation of the casing using the downhole sensor; and recording the one or more perforation properties locally in the tool string.

[0097] Clause 14. The method of clause 13, wherein perforating the casing and determining one or more perforation properties are performed in one trip of the tool string into the borehole.

[0098] Clause 15. The method of clause 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and measuring one or more perforation values while moving the downhole sensor in the uphole direction.

[0099] Clause 16. The method of clause 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and stopping uphole movement of the downhole sensor while measuring one or more perforation values.

[0100] Clause 17. A tool string comprising: a perforation tool; and a casing measuring sub connected to the perforation tool in a downhole direction from the perforation tool, wherein the casing measuring sub includes: a casing reading system, a processor, and a hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising: receiving data from the casing reading system, and analyzing the data to detect one or more properties associated with a casing of a borehole.

[0101] Clause 18. The tool string of clause 17, wherein the casing reading system includes at least one optical sensor.

[0102] Clause 19. The tool string of clause 17, wherein the casing reading system includes at least one induction sensor.

[0103] Clause 20. The tool string of clause 17, wherein the tool string further includes a plug tool positioned in the downhole direction relative to the casing measuring sub.

[0104] The specific embodiments described above have been illustrated by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.

[0105] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Examples

Embodiment Construction

[0019]One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0020]When introducing elements of various embodime...

PRIORITY

[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 710,808, filed Oct. 23, 2024, and titled TECHNIQUES FOR MONITORING DOWNHOLE DATA USING A DOWNHOLE SENSOR, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The present disclosure generally relates to techniques for monitoring wellbore data using a downhole sensor. This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as an admission of any kind.

[0003] Acoustic and other recording devices have been used to measure, sense, and record dimensions of downhole wellbore components, including casing, cement, and perforation hole sizes. For casing, such information from these devices can be used to determine casing ovalities, assess thread damage, and / or casing wall loss. Additionally, such information can be used to record imperfections and / or marks in the wall of the casing, such as a slip mark from a fracturing plug. Powerful readers can penetrate through the casing and measure dimensions of materials on the outside of the casing, such as cement. The information from these readers can then be used to assess the integrity and presence of cement around the casing.

[0004] In order to measure perforating hole size for a particular stage, measurement is typically performed prior to pumping a stimulation into the stage and after pumping the stimulation into the stage. Measuring perforating hole size is typically performed to verify charge performance as well as to monitor cluster erosion efficiency. However, such measurement runs are performed separately from a plug and perf bottom hole assembly run and can be quite costly. Accordingly, improvements in gathering data on wellbore dimensions and conditions are highly desirable.SUMMARY

[0005] A summary of certain embodiments described herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure.

[0006] Certain embodiments of the present disclosure are directed to techniques for monitoring wellbore data using a downhole sensor. In one embodiment, a wellbore reader may be incorporated into a bottomhole assembly (BHA) to gather data associated with wellbore dimensions and conditions during a wellbore operation. For example, the wellbore operation may include a plug and perf operation. Such wellbore dimensions and conditions may include perforation size.

[0007] After the wellbore reader has gathered the data, it may be stored locally and retrieved on surface, or the data may be transmitted to the surface for analysis. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing. Additional parameters this tool will capture are velocities, orientation, and inclination of the tool both when RIH and during perforating.

[0008] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0009] Various refinements of the features noted above may be undertaken in relation to various aspects of the present disclosure. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. The brief summary presented above is intended to familiarize the reader with certain aspects and contexts of embodiments of the present disclosure without limitation to the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, non-schematic drawings should be considered as being to scale for some embodiments of the present disclosure, but not to scale for other embodiments contemplated herein. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0011] FIG. 1 illustrates a drilling system and downhole environment, according to some embodiments of the present disclosure.

[0012] FIGS. 2-1 and 2-2 illustrate a downhole environment in which a tool string creates and measures a perforation in a casing, according to some embodiments of the present disclosure.

[0013] FIG. 3 is a perspective view of a measuring sub including an optical casing reader, according to some embodiments of the present disclosure.

[0014] FIG. 4 is a side cross-sectional view of a measuring sub including an optical casing reader, according to some embodiments of the present disclosure.

[0015] FIG. 5 is a perspective view of a measuring sub including an induction casing reader, according to some embodiments of the present disclosure.

[0016] FIG. 6 is a side cross-sectional view of a measuring sub including an induction casing reader, according to some embodiments of the present disclosure.

[0017] FIG. 7 is a flowchart illustrating a method of measuring a casing property in a downhole environment, according to some embodiments of the present disclosure.

[0018] FIG. 8 is a flowchart illustrating a method of measuring a perforation property in a downhole environment, according to some embodiments of the present disclosure.DETAILED DESCRIPTION

[0019] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0020] When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,” and “the” are intended to mean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0021] As used herein, the terms “connect,”“connection,”“connected,”“in connection with,” and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element.” Further, the terms “couple,”“coupling,”“coupled,”“coupled together,” and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements.” As used herein, the terms “up” and “down,”“uphole” and “downhole”, “upper” and “lower,”“top” and “bottom,” and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top (e.g., uphole or upper) point and the total depth along the drilling axis being the lowest (e.g., downhole or lower) point, whether the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0022] In addition, as used herein, the terms “real time”, “real-time”, or “substantially real time” may be used interchangeably and are intended to described operations (e.g., computing operations) that are performed without any human-perceivable interruption between operations. For example, as used herein, data relating to the systems described herein may be collected, transmitted, and / or used in control computations in “substantially real time” such that data readings, data transfers, and / or data processing steps occur once every second, once every 0.1 second, once every 0.01 second, or even more frequent, during operations of the systems (e.g., while the systems are operating). In addition, as used herein, the terms “automatic” and “automated” are intended to describe operations that are performed or caused to be performed, for example, by a processing system (i.e., solely by the processing system, without human intervention). In addition, as used herein, the term “approximately equal to” may be used to mean values that are relatively close to each other (e.g., within 5%, within 2%, within 1%, within 0.5%, or even closer, of each other).

[0023] As mentioned above, certain embodiments of the present disclosure are directed to techniques for monitoring wellbore data using a downhole sensor. In one embodiment, a wellbore or casing reader may be incorporated into a bottomhole assembly (BHA) to gather data associated with wellbore dimensions and conditions during a wellbore operation. For example, the wellbore operation may include a plug and perforation (“plug and perf”) operation. Such wellbore dimensions and conditions may include perforation size, perforation shape, perforation aspect ratio, perforation depth, etc.

[0024] After the wellbore or casing reader has gathered the spatial data, the spatial data may be transmitted to the surface for analysis. The spatial data may be transmitted to the surface by wired communication, wireless communication, or by storage of the spatial data on a local hardware storage device in the downhole environment for subsequently tripping of the tool to the surface. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing.

[0025] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0026] In certain embodiments, a measuring sub (e.g., a wellbore or casing reader) is provided in a tool string. In one embodiment, the measuring sub may be provided between a perforation gun section and a firing head of the tool string. However, in other embodiments, the measuring sub may be disposed in any other suitable position in the tool string. In certain embodiments, the measuring sub can run off battery power and / or have memory on board. In other embodiments, the measuring sub can receive power through a wired connection, such as other components of the tool string, wireline, coiled tubing, or any other suitable source. In certain embodiments, it may benefit to position the measuring sub in the tool string as low as possible in order to obtain the most and / or most valuable types of information. For instance, the position of the measuring sub may be conveyed to the lowest depth of a bottom hole assembly of the tool string.

[0027] FIG. 1 illustrates an embodiment of a drilling system and downhole environment. FIG. 1 shows one example of a drilling system 100 for drilling an earth formation 101 to form a borehole 102. The drilling system 100 includes a drill rig 103 used to turn a drilling assembly 104 which extends downward into the borehole 102. The drilling assembly 104 may include a drill string 105 and a bottomhole assembly (BHA) 106 attached to the downhole end of the drill string 105. Where the drilling system 100 is used for drilling formation, a drill bit 110 can be included at the downhole end of the BHA 106.

[0028] The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and can transmit rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 may further include additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid 111 is pumped from the surface. The drilling fluid 111 discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, for lifting cuttings out of the borehole 102 as it is being drilled, and for preventing the collapse of the borehole 102. The drilling fluid 111 carries drill solids including drill fines, drill cuttings, and other swarf from the borehole 102 to the surface. The drill solids can include components from the earth formation 101, the drilling assembly 104 itself, from other man-made components (e.g., plugs, lost tools / components, etc.), or combinations thereof.

[0029] The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and / or the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (MWD) tools, logging-while-drilling (LWD) tools, downhole motors, underreamers, directional steering tools, section mills, hydraulic disconnects, jars, vibration dampening tools, other components, or combinations of the foregoing.

[0030] In general, the drilling system 100 may include other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, safety valves, centrifuges, shaker tables, and rheometers). Additional components included in the drilling system 100 may be considered a part of the surface system (e.g., drill rig 103, drilling assembly 104, drill string 105, or a part of the BHA 106, depending on their locations and / or use in the drilling system 100).

[0031] The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits, roller cone bits, impregnated bits, or coring bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing 107 lining the borehole 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the borehole 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface by the drilling fluid 111 or may be allowed to fall downhole. The conditions of the equipment of the drilling system 100, the formation 101, the borehole 102, the drilling fluid 111, or other part of the wellsite can change during operations.

[0032] After construction of the wellbore, the casing 107 may be installed, perforated, or modified during production. In some embodiments, a wireline (or other conveyance system, such as coiled tube) tool string may be delivered into the wellbore to measure or monitor the casing or wellbore conditions, as well as perforate or otherwise modify the casing. In some embodiments according to the present disclosure, a tool string includes measuring sub configured to measure at least one casing property of the casing and store data associated with the casing property on a hardware storage device local to the tool string. In some embodiments according to the present disclosure, a tool string includes both a perforation tool and a measuring sub configured to measure at least one perforation property of a resulting perforation, such that the perforation can be made in the casing and the perforation property can be measured in a single trip of the tool string downhole (such as in a single Plug-and-Perf trip). In at least one embodiment, the perforation tool is located in the tool string uphole from the measuring sub, such that the measuring sub is configured to measure a perforation property as the tool string is moved uphole after each firing of a perforation tool. In other words, the tool string may be moved continuously or sequentially uphole to each perforation location within a target zone, with the measuring sub passing by the previous perforation location (and measuring the perforations therein) during transit to the next perforation location.

[0033] In some embodiments, a measuring sub includes an optical measurement system. For example, the optical measurement system includes an optical sensor array that can detect casing dimensions using camera and visual analysis. In some embodiments, a measuring sub includes an induction measurement system. For example, the induction measurement system includes an induction sensor array that can detect casing dimensions and / or material using electromagnetic analysis.

[0034] FIG. 2-1 and FIG. 2-2 illustrate an embodiment of a tool string 212 that is tripped into a formation 201 through a borehole 202 having a casing 207. In some embodiments, the tool string 212 includes a plug tool 214 that may be positioned in a borehole 202. The plug tool 214 may be deployed to contact the casing 207 and create a fluid seal between the plug tool 214 and the casing 207 to isolate a portion of the borehole 202. In some embodiments, the plug tool 214 is deployed in the casing 207 before perforation of the casing 207 with a perforation tool 216 of the tool string 212. In some embodiments, the tool string 212 includes at least one perforation tool 216. In some embodiments, the tool string 212 includes a plurality of perforation tools 216 in series in the axial direction of the tool string 212.

[0035] The perforation tool(s) 216 is configured to create perforations 218 in the casing 207 and / or into the formation 201 using one or more perforating mechanisms, such as guns 217. For example, the guns 217 may be single-use mechanisms with a single charge loaded in each gun 217. In some embodiments, a perforation tool 216 has a plurality of perforating mechanisms, and the tool string 212 has a plurality of perforation tools 216 that may each be used once in a single trip of the tool string 212 into the borehole 202. In some embodiments, the perforation tool 216 is configured to provide multiple perforations per each perforating mechanism.

[0036] In some embodiments, the perforations 218 provide fluid communication between the borehole 202 and the formation 201. For example, the formation 201 includes a formation fluid, such as water, oil, gas, or a combination thereof, that may flow into the wellbore during production operations. In some examples, a fluid is provided into and / or through the borehole 202 to enter the formation 201, such as a drilling fluid and / or a proppant carrier fluid to provide a proppant into the formation 201 to support the formation 201 during production.

[0037] In some embodiments, the tool string 212 includes a measuring sub 220 configured to measure one or more properties of the casing 207 and / or one or more properties of the perforation(s) 218. In some embodiments, the measuring sub 220 is configured to measure a casing property, such as casing ovality of an inner surface of the casing 207, aspect ratio of the inner surface of the casing 207, casing thickness, casing roughness, or other casing properties. In some embodiments, the measuring sub 220 is configured to measure a perforation property, such as perforation ovality, perforation diameter, perforation sharpness, perforation depth (through the casing 207 and / or the formation 201) or other perforation properties. In some embodiments, the measuring sub 220 is configured to additionally measure at least one property of the casing at the location of the perforation, such as deformation, curvature, cracking, or other properties of the interface between the casing and the perforation. The perforation tool(s) 216 is located in the uphole direction 222 of the borehole 202 relative to the measuring sub 220.

[0038] Referring now to FIG. 2-2, the tool string 212 may be moved in an uphole direction 222 of the borehole 202 after the perforation tool 216 perforates the casing 207. In some embodiments, the measuring sub 220 is moved in the uphole direction 222 until the measuring sub 220 is axially aligned in the borehole 202 with the perforation(s) 218 in the casing 207. In some embodiments, the measuring sub 220 is configured to measure at least one casing property and / or at least one perforation property while moving relative to the casing 207 and / or formation 201. In some examples, the measuring sub 220 measures the casing 207 and / or perforation(s) 218 substantially continuous while moving to assemble an image of the casing and / or perforation(s) 218. In some embodiments, the measuring sub 220 is configured to measure at least one casing property and / or at least one perforation property while stationary relative to the casing 207 and / or formation 201. In some examples, the measuring sub 220 (and tool string 212) may be stopped proximate to the casing 207 and / or perforation(s) 218 to measure the casing and / or perforation property via a camera that images the inner surface of the casing 207 and / or the perforation(s) 218.

[0039] FIG. 3 through FIG. 6 illustrate embodiments of measuring subs that may be tripped into the borehole in a tool string including a perforation tool(s) that may measure at least one perforation property in the same trip as the perforation(s) is created in the casing. In some embodiments, the measuring sub includes a casing reader configured to measure casing properties of a casing and / or perforation properties of perforation(s) therein. FIG. 3 is a perspective view of an embodiment of a measuring sub 320 including an optical casing reader.

[0040] In some embodiments, the measuring sub 320 includes a housing 324 (transparent in FIG. 3). In some embodiments, the housing 324 is transparent to light in a wavelength detectable by an optical sensor 326 of the measuring sub 320. In some embodiments, the housing 324 is made of the transparent material. In some embodiments, the housing 324 includes a window of transparent material that is proximate to the optical sensor 326. The optical sensor collects spatial data of the surrounding environment of the measuring sub. In some embodiments, the spatial data is two-dimensional data. In some embodiments, the spatial data is three-dimensional data. In some embodiments, the optical sensor 326 is or includes a visible light camera. In some embodiments, the optical sensor 326 is or includes an invisible wavelength light camera, such as an infrared light camera or an ultraviolet light camera. In some embodiments, the optical sensor 326 is or includes a laser sensor. In some embodiments, the optical sensor 326 is or includes a depth camera, such as a time-of-flight camera or a stereographic camera configured to determine depth information while imaging an object in the field of view of the camera.

[0041] In some embodiments, the optical sensor 326 further includes an illumination source. In some embodiments, an illumination source is located in the measuring sub 320 with the optical sensor 326 such that the optical sensor 326 can detect the reflected light from the illumination source.

[0042] In some embodiments, the optical sensor 326 is one of a plurality of optical sensors 326 of the measuring sub 320. In some embodiments, the plurality of optical sensors 326 is arranged in an array with overlapping field-of-views to measure the casing property and / or perforation property. In some embodiments, the plurality of optical sensors 326 is arranged circumferentially around the measuring sub 320 to capture an image or other optical information in a full circumference around the measuring sub 320 and a full inner surface of the casing of the borehole.

[0043] In some embodiments, the plurality of optical sensors 326 is arranged with at least a first optical sensor and a second optical sensor displaced in an axial direction with the first optical sensor located in a downhole direction relative to the second optical sensor. For example, the first optical sensor may be one of a first set of circumferential optical sensors 326, and the second optical sensor may be one of a second set of circumferential optional sensors 326 that is positioned axially displaced from the first set. In some embodiments, at least one optical sensor 326 is rotationally aligned with the perforation tool outlets, such as the guns described in relation to FIG. 2-1, such that the optical sensor is rotationally aligned with a perforation created thereby upon axial movement of the tool string in the uphole direction. In some embodiments, a plurality of optical sensors 326 are rotationally aligned with a plurality of perforation tool outlets, such as each oriented at 90° spacing around the rotational axis of the tool string or 120° spacing around the rotational axis.

[0044] As described herein, a measuring sub according to the present disclosure is configured to measure and record a casing property and / or a perforation property after perforation of the casing with a perforation tool in a single trip of the tool string into the borehole without tripping the perforation tool out of the borehole. In some embodiments, the measuring sub 320 includes an onboard power supply, such as a battery 328, that allows the measuring sub to record the measurement(s) to a local hardware storage device 330 by a processor 331. In some embodiments, the processor is any microprocessor capable of data communication with the optical sensor(s) 326 to receive the optical information and the hardware storage device 330 to execute instructions stored thereon. The processor 331 may then store measurements on the hardware storage device 330. In some embodiments, the battery 328 or other power supply is configured to provide electrical power at least to the optical sensor(s) 326 and / or hardware storage device 330.

[0045] In some embodiments, the hardware storage device(s) 330 is a non-transient storage device including any of RAM, ROM, EEPROM, CD-ROM or other optical disk storage (such as CDs, DVDs, etc.), magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.

[0046] In some embodiments, the processor(s) 331 is a central processing unit (CPU) that performs general computing tasks for the measuring sub 320. In some embodiments, the processor(s) 331 is or is part of a system on chip (SoC) that is dedicated to controlling or communicating with one or more subsystems of the measuring sub 320. In some embodiments, the processor 331 is in data communication with the hardware storage device 330 to execute instructions stored thereon that cause the processor 331 to perform any of the methods or a portion of any of the methods described herein.

[0047] FIG. 4 is a side cross-sectional view of an embodiment of a measuring sub 420 including an optical casing reader. In some embodiments, the measuring sub 420 includes a body 432 that supports a housing 424. In some embodiments, the housing 424 is positioned radially outside of and overlapping at least one optical sensor 426. In some embodiments, the housing 424 is positioned radially outside of and overlapping the battery 428, hardware storage device 430, and / or processor 431.

[0048] FIG. 5 is a perspective view of an embodiment of a measuring sub 520 including an induction casing reader. In some embodiments, the measuring sub 520 includes a housing 524 (transparent in FIG. 5). In some embodiments, the housing 524 is transparent to electromagnetic fields detectable by an induction sensor 534 and / or produced by an induction coil 536 of the measuring sub 520. In some embodiments, the housing 524 is made of a magnetically transparent material, such as a polymer or a non-magnetic metal or metal alloy. In some embodiments, the housing 524 includes a window of magnetically transparent material that is proximate to the induction sensor 534 and / or induction coil 536. In some embodiments, the housing 524 includes one or more apertures therein such that the induction sensor 534 and / or induction coil 536 is exposed to the borehole fluid or other contents of the borehole. In such examples, the housing 524 may be or include a ferromagnetic material without substantially impacting the magnetic field applied by the induction coil(s) 536 to the casing.

[0049] In some embodiments, the induction coil 536 further includes a magnetic field source. For example, the induction coil 536 may include an electromagnetic coil that is selectively energized to produce a magnetic field emanating from the measuring sub 520 (e.g., through the housing 524) that induces a current in the casing. In some embodiments, the magnetic field source includes a permanent magnetic that induces a current as the permanent magnet moves past the casing. In some embodiments, the magnetic field source includes both a permanent magnet and an electromagnet. In some examples, the current may be induced as an eddy current in the casing (such as a steel casing or other ferromagnetic casing) that produces an induced magnetic field from the casing. The induction sensor 534 may then detect the induced magnetic field from the casing. Based at least partially on the detected strength of the induced magnetic field, the induction sensor 534 and / or a processor 531 in data communication with the induction sensor 534 may determine a distance from the induction sensor 534 to the casing, a thickness of the casing, a casing material, a void (e.g., a perforation) in the casing, and other casing properties. In some embodiments, an induction coil 536 is located in the measuring sub 520 with the induction sensor 534 such that the induction sensor 534 can detect an induced magnetic field from the casing induced by the induction coil 536.

[0050] The induction sensor 534 collects spatial data of the surrounding environment of the measuring sub. In some embodiments, the spatial data is two-dimensional data. In some embodiments, the spatial data is three-dimensional data. In some embodiments, the induction sensor 534 is one of a plurality of induction sensors 534 of the measuring sub 520. In some embodiments, the plurality of induction sensors 534 is arranged in an array with overlapping field-of-views to measure the casing property and / or perforation property. In some embodiments, the plurality of induction sensors 534 is arranged circumferentially around the measuring sub 520 to capture an induction image (such as a matrix of induction measurements at various locations) or other induction information in a full circumference around the measuring sub 520 and a full inner surface of the casing of the borehole.

[0051] In some embodiments, the plurality of induction sensors 534 is arranged with at least a first induction sensor and a second induction sensor displaced in an axial direction with the first induction sensor located in a downhole direction relative to the second induction sensor. For example, the first induction sensor may be one of a first set of circumferential induction sensors 534, and the second induction sensor may be one of a second set of circumferential induction sensors 534 that is positioned axially displaced from the first set. In some embodiments, at least one induction sensor 534 is rotationally aligned with the perforation tool outlets, such as the guns described in relation to FIG. 2-1, such that the induction sensor is rotationally aligned with a perforation created thereby upon axial movement of the tool string in the uphole direction. In some embodiments, a plurality of induction sensors 534 are rotationally aligned with a plurality of perforation tool outlets, such as each oriented at 90° spacing around the rotational axis of the tool string or 120° spacing around the rotational axis.

[0052] As described herein, a measuring sub according to the present disclosure is configured to measure and record a casing property and / or a perforation property after perforation of the casing with a perforation tool in a single trip of the tool string into the borehole without tripping the perforation tool out of the borehole. In some embodiments, the measuring sub 520 includes an onboard power supply, such as a battery 528, that allows the measuring sub to record the measurement(s) to a local hardware storage device 530 by a processor 531. In some embodiments, the processor is any microprocessor capable of data communication with the optical sensor(s) 526 to receive the optical information and the hardware storage device 530 to execute instructions stored thereon. The processor 531 may then store measurements on the hardware storage device 530. In some embodiments, the battery 528 or other power supply is configured to provide electrical power at least to the induction sensors 534, the induction coils 536 and / or hardware storage device 530.

[0053] In some embodiments, the hardware storage device(s) 530 is a non-transient storage device including any of RAM, ROM, EEPROM, CD-ROM or other optical disk storage (such as CDs, DVDs, etc.), magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer.

[0054] In some embodiments, the processor(s) 531 is a central processing unit (CPU) that performs general computing tasks for the measuring sub 520. In some embodiments, the processor(s) 531 is or is part of a system on chip (SoC) that is dedicated to controlling or communicating with one or more subsystems of the measuring sub 520. In some embodiments, the processor 531 is in data communication with the hardware storage device 530 to execute instructions stored thereon that cause the processor 531 to perform any of the methods or a portion of any of the methods described herein.

[0055] By using an array of induction coils 536, induction can be put into the casing and while traveling the induction sensors 534 that are in an axial row can sense how fast the tool string is moving based on sensing an induction decay rate. For example, an induced current will decay when the inducing magnetic field (e.g., that of the induction coil 536) is removed. In some embodiments, the inducing magnetic field is removed by displacing the induction coil(s) 536 axially away from the region of the casing with the induced current. In some embodiments, the inducing magnetic field is removed by deactivating the induction coil 536, such as de-energizing an electromagnetic thereof.

[0056] The strength of the measured induced magnetic field and the induction decay rate of the induced magnetic field is, in some embodiments, used to sense casing dimensions: diameters, ovalities, thicknesses, etc. A thin casing material may saturate and produce an induced magnetic field of limited strength. A measured strength of a magnetic field decreases exponentially relative to a distance from the source (i.e., the casing), allowing a determination of a distance to the casing (e.g., diameter and / or ovalities when measured in a plurality of directions from the measuring sub).

[0057] In some embodiments, the induction coils 536 produce a magnetic field directed at a portion of the casing including a perforation. No electrical current is inducing in the perforation, and, therefore, no induced magnetic field is detected by the induction sensors 534. Induction sensors 534 that are axially in line or near other sensors will be able to detect this lack of induction in the casing, and by using the speed of the measuring sub relative to the casing (in an axial direction, a rotational direction, or both) the induction sensors 534 and processor 531 detect an approximate perforation size. In some embodiments, the array of induction sensors 534 measures the induced magnetic field and / or induction decay rate at a plurality of locations while stationary or substantially stationary relative to the casing. The relative strength of the induced magnetic field and / or induction decay rate at each location in the array may allow the processor to reconstruct an image of the casing at that location in the borehole.

[0058] FIG. 6 is a side cross-sectional view of an embodiment of a measuring sub 620 including an induction casing reader. In some embodiments, the measuring sub 620 includes a body 632 that supports a housing 624. In some embodiments, the housing 624 is positioned radially outside of and overlapping at least one induction sensor 634 and / or induction coil 636. In some embodiments, the housing 624 is positioned radially outside of and overlapping the battery 628, hardware storage device 630, and / or processor 631.

[0059] In some embodiments, a circumferential set of induction sensors 634 and / or induction coils 636 includes at least one induction sensor 634 and one induction coil 636. In some embodiments, a circumferential set includes a plurality of induction sensors 634 or a plurality of induction coils 636, with a second set positioned axially displaced in the body 632. As described in relation to FIG. 5, in some embodiments, the plurality of induction sensors 634 and / or the plurality of induction coils 636 are positioned in the body 632 without a housing 624 covering the plurality of induction sensors 634 and / or the plurality of induction coils 636. In some embodiments, the plurality of induction sensors 634 and / or the plurality of induction coils 636 are therefore configured to provide and / or detect magnetic fields without interference caused by the housing.

[0060] In some embodiments, a measuring sub according to the present disclosure includes a sonar sensor that uses directional acoustic waves to measure distances to the casing and supplement the spatial data from the optical sensor(s) described in relation to FIGS. 3 and 4 and / or the spatial data from the induction sensor(s) described in relation to FIGS. 5 and 6.

[0061] FIG. 7 is a flowchart illustrating an embodiment of a method 738 of measuring a casing property in a downhole environment. In some embodiments, the method 738 includes providing a downhole sensor incorporated into a tool string at 740. For example, the downhole sensor may be any of the measuring subs, optical sensors, induction sensors, or combinations thereof described herein. In some embodiments, the tool string includes a measuring sub with a processor, hardware storage device, and power supply within the measuring sub to allow operation of the measuring sub independently of power or data communication with other components. In some embodiments, the tool string includes one or more perforation tools uphole of the measuring sub. In some embodiments, the tool string includes a plug tool downhole of the measuring sub. In some embodiments, the tool string includes at least one optical sensor and / or illumination source. In some embodiments, the tool string includes at least one induction sensor and / or induction coil. In some embodiments, the tool string includes both at least one optical sensor and / or illumination source and at least one induction sensor and / or induction coil. For example, a tool string may include at least one optical sensor, at least one illumination source, at least one induction sensor, and at least one induction coil. Such systems may allow additional information or redundancy for measurement of casing and / or perforation properties. For example, some casing materials may not be electrically conductive to produce an induced magnetic field, and the optical sensors may provide information in those regions of the casing. In some examples, a borehole fluid present in the borehole may limit and / or prevent the use of optical measurements of the casing.

[0062] The method 738, in some embodiments, includes positioning the tool string in a downhole environment of a borehole at 742. In some embodiments, positioning the tool string may include moving the tool string in an axial direction of the borehole. For example, positioning the tool string may include moving the tool string axially downhole (which may include horizontal movement of the tool string). In some examples, positioning the tool string may include moving the tool string uphole. In some embodiments, positioning the tool string may include rotation of the tool string in the borehole.

[0063] In some embodiments, positioning the tool string may include moving the tool string via a wireline conveyance mechanism in the borehole. In some embodiments, positioning the tool string may include moving the tool string via a coiled tubing conveyance mechanism in the borehole. In some embodiments, positioning the tool string may include moving the tool string via a drill pipe or other substantially rigid conveyance mechanism in the borehole.

[0064] The method 738 further includes, in some embodiments, determining one or more casing properties of a casing using the downhole sensor at 744. As described herein, determining one or more casing properties of a casing using the downhole sensor may include optical and / or induction measurements. In some embodiments, spatial data including optical measurements is collected by an optical sensor or array of optical sensors, such as described in relation to FIG. 3 and FIG. 4. For example, the optical sensor may be a visible light sensor, an infrared sensor, an ultraviolet sensor, other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0065] In some embodiments, the optical sensor detects light reflected by the casing or other features of the borehole from an illumination source of the measuring sub and / or tool string. For example, the illumination source(s) may be located on the measuring sub and positioned within an array of optical sensors. In some examples, the illumination source(s) may be located adjacent to and / or integrated with an optical sensor. In some embodiments, the illumination source is a visible light source, an infrared source, an ultraviolet source, a source of other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0066] In some embodiments, the optical sensor(s) is a depth camera. For example, the optical sensor(s) and illumination source may be a time-of-flight camera. In some examples, the optical sensors have overlapping fields-of-view and may produce depth measurements by stereoscopic comparison of overlapping features in the overlapping fields-of-view.

[0067] In some embodiments, spatial data including induction measurements is collected by an induction sensor or array of induction sensors, such as described in relation to FIG. 5 and FIG. 6. For example, the induction sensor(s) may measure a strength of an induced magnetic field from an electrically conductive casing, a direction of the induced magnetic field, a decay rate of the induced magnetic field, or other properties of a magnetic field of the casing.

[0068] In some embodiments, an array of induction sensors may allow the measurement of the induced magnetic field relative to an induction coil that induces a current in the electrically-conductive casing to produce the induced magnetic field. In some embodiments, the array of induction coils is interspersed with the induction sensors. In some embodiments, the array of induction coils is axially spaced relative to circumferential sets of the induction sensors.

[0069] Based on the measured direction and strength of the magnetic field, and the changes of such over time, the induction sensors and / or processor connected thereto determines one or more casing properties, such as casing material, casing thickness, casing diameter, casing ovality, etc. The method 738 further includes, in some embodiments, recording the one or more casing properties locally in the tool string at 746. For example, the one or more casing properties (determined by the optical sensor, induction sensor, processor, or combinations thereof) may be recorded locally on the tool string on a hardware storage device thereof. In some embodiments, the data stored on the hardware storage device is subsequently retrieved at the surface of the borehole and / or the data is transmitted to the surface from the tool string for analysis.

[0070] FIG. 8 is a flowchart illustrating an embodiment of a method 848 of measuring a perforation property in a downhole environment. In some embodiments, the method includes providing a downhole sensor and perforation tool incorporated into a tool string at 850. The tool string may include a downhole sensor, such as described in relation to FIG. 7, and a perforation tool with one or more perforating mechanisms, such as described in relation to FIG. 2-1 and FIG. 2-2. In some embodiments, the downhole sensor is configured to measure the perforation created by the perforating tool in a single trip into the borehole without removing the tool string.

[0071] The method 848 includes, in some embodiments, positioning the tool string in a downhole environment of a borehole at 842. In some embodiments, positioning the tool string in a downhole environment is similar to that described in relation to FIG. 7. In some embodiments, positioning the tool string in the downhole environment includes positioning the perforation tool at a target location or zone within the borehole. In some examples, the tool string may be located at a target location for the perforation tool and subsequently moved to measure the perforation with the downhole sensor.

[0072] In some embodiments, the method 848 further includes perforating the casing with the perforation tool at 852. As described in relation to FIG. 2-1, in some embodiments, perforating the casing includes creating perforations through the casing uphole of the downhole sensor. In some embodiments, the perforation tool includes a plurality of perforating guns that produce a plurality of perforations through the casing at an axial position in the borehole. Upon creation of the perforations, the downhole sensor allows measurement of one or more perforation properties to evaluate the success of the perforation creation without tripping the perforation tool out of the borehole. In some embodiments, a series of perforation tools allow the perforation of the borehole casing in a plurality of axial locations.

[0073] In some embodiments, perforating the casing with the perforation tool at 852 is performed after measuring at least one previously existing perforation in the casing. For example, the measuring sub may collect spatial data and / or measure at least one perforation property of a perforation prior to perforating the casing with the perforation tool. In some embodiments, the previously formed perforation is formed earlier in the same trip of the tool string in the downhole environment. In some embodiments, the previously formed perforation is formed in a separate and previous trip of the tool string or a different tool string in the downhole environment.

[0074] The method 848 further includes determining one or more casing properties of a casing using the downhole sensor at 844. In some embodiments, determining one or more casing properties is similar to that described in relation to FIG. 7. The method 848 further includes recording the one or more casing properties locally in the tool string at 846. In some embodiments, recording the one or more casing properties is similar to that described in relation to FIG. 7.

[0075] In some embodiments, the method 848 includes determining one or more perforation properties of a perforation of the casing using the downhole sensor at 854 and recording the one or more perforation properties locally in the tool string at 856. The perforation properties may include any of a perforation area, perforation depth, perforation aspect ratio or ovality, perforation edge shape, perforation location, perforation orientation, or other perforation properties. As described herein, determining one or more perforation properties of a casing using the downhole sensor may include optical and / or induction measurements. In some embodiments, optical measurements are collected by an optical sensor or array of optical sensors, such as described in relation to FIG. 3 and FIG. 4. For example, the optical sensor may be a visible light sensor, an infrared sensor, an ultraviolet sensor, other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0076] In some embodiments, the optical sensor detects light reflected by the perforation edges or other features of the borehole from an illumination source of the measuring sub and / or tool string. For example, the illumination source(s) may be located on the measuring sub and positioned within an array of optical sensors. In some examples, the illumination source(s) may be located adjacent to and / or integrated with an optical sensor. In some embodiments, the illumination source is a visible light source, an infrared source, an ultraviolet source, a source of other selected wavelengths or ranges of wavelengths, or combinations thereof.

[0077] In some embodiments, the optical sensor(s) is a depth camera. For example, the optical sensor(s) and illumination source may be a time-of-flight camera. In some examples, the optical sensors have overlapping fields-of-view and may produce depth measurements by stereoscopic comparison of overlapping features in the overlapping fields-of-view.

[0078] In some embodiments, induction measurements are collected by an induction sensor or array of induction sensors, such as described in relation to FIG. 5 and FIG. 6. For example, the induction sensor(s) may measure a strength of an induced magnetic field from an electrically conductive casing, a direction of the induced magnetic field, a decay rate of the induced magnetic field, or other properties of a magnetic field of the casing. For example, a region of the casing that exhibits less or no induced magnetic field relative to a surrounding region of the casing indicates a perforation where the casing material has been removed or displacement.

[0079] In some embodiments, an array of induction sensors may allow the measurement of the induced magnetic field relative to an induction coil that induces a current in the electrically-conductive casing to produce the induced magnetic field. In some embodiments, the array of induction coils is interspersed with the induction sensors. In some embodiments, the array of induction coils is axially spaced relative to circumferential sets of the induction sensors.

[0080] After the wellbore reader has gathered the data, it may be stored locally and retrieved on surface, or the data may be transmitted to the surface for analysis. The data may be analyzed to determine the success and / or performance of the wellbore operation. For example, the data may be used to analyze plug success (e.g., whether debris is present during setting), casing dimensions (e.g., casing ovalities), cluster erosion efficiency, initial perforation hole sizes, and cement integrity prior and post fracturing. In some embodiments, the optical and / or induction sensors measure velocities, orientation, and inclination of the tool string when running in hole and during perforating the casing.

[0081] Additionally, a large data model may be built using the data gathered by the wellbore reader and / or the resulting analysis of the data. For example, the large data model can build relationships between tool performance and downhole factors. The large data model may also be used to prove certain performance characteristics, such as perforation size. Using such relationships, tool function and completion planning can be fine-tuned to a fully optimized state. Such optimization may then contribute to large efficiency gains in fracturing performance, thereby reducing costs and expenditures and increasing production.

[0082] Although certain embodiments of the present disclosure are described with respect to measuring data associated with a perforation operation, it should be understood that such embodiments are not limited to such operations. Indeed, embodiments of the present disclosure may be applied to gathering and analyzing data associated with any type of wellbore operation using a downhole sensor as described herein. In certain embodiments, the measuring sub (e.g., a wellbore reader) may include an acoustic sensor, or any other suitable type of sensor.

[0083] The present disclosure contemplates devices, systems, and methods for downhole measurements according to at least the following clauses:

[0084] Clause 1. A measuring sub of a tool string, comprising: a casing reading system; a processor; and a hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising: receiving spatial data from the casing reading system; and analyzing the spatial data to detect one or more properties associated with a casing of a borehole.

[0085] Clause 2. The measuring sub of clause 1, wherein the casing reading system includes an optical array.

[0086] Clause 3. The measuring sub of clause 1, wherein the casing reading system includes an induction sensor array.

[0087] Clause 4. The measuring sub of clause 1, wherein the spatial data includes visual data of the casing.

[0088] Clause 5. The measuring sub of clause 1, wherein the spatial data includes material data of the casing.

[0089] Clause 6. The measuring sub of clause 1, wherein the spatial data includes an aspect ratio of the casing.

[0090] Clause 7. The measuring sub of clause 1, wherein the spatial data includes perforation data of the casing.

[0091] Clause 8. The measuring sub of clause 1, wherein the spatial data includes thickness data of the casing.

[0092] Clause 9. The measuring sub of clause 1, wherein the spatial data includes a plurality of measurements associated with overlapping axial positions in the borehole.

[0093] Clause 10. The measuring sub of clause 1, wherein the instructions further cause the processor to store the one or more properties associated with the casing locally to the measuring sub.

[0094] Clause 11. The measuring sub of clause 10, wherein the one or more properties associated with the casing are stored on the hardware storage device.

[0095] Clause 12. A method of measuring a casing property, the method comprising: providing a downhole sensor incorporated into a tool string; positioning the tool string in a downhole environment of a borehole; determining one or more casing properties of a casing using the downhole sensor; and recording the one or more casing properties locally in the tool string.

[0096] Clause 13. The method of clause 12, wherein the tool string further includes a perforation tool, and further comprising: perforating the casing with the perforation tool; determining one or more perforation properties of a perforation of the casing using the downhole sensor; and recording the one or more perforation properties locally in the tool string.

[0097] Clause 14. The method of clause 13, wherein perforating the casing and determining one or more perforation properties are performed in one trip of the tool string into the borehole.

[0098] Clause 15. The method of clause 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and measuring one or more perforation values while moving the downhole sensor in the uphole direction.

[0099] Clause 16. The method of clause 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and stopping uphole movement of the downhole sensor while measuring one or more perforation values.

[0100] Clause 17. A tool string comprising: a perforation tool; and a casing measuring sub connected to the perforation tool in a downhole direction from the perforation tool, wherein the casing measuring sub includes: a casing reading system, a processor, and a hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising: receiving data from the casing reading system, and analyzing the data to detect one or more properties associated with a casing of a borehole.

[0101] Clause 18. The tool string of clause 17, wherein the casing reading system includes at least one optical sensor.

[0102] Clause 19. The tool string of clause 17, wherein the casing reading system includes at least one induction sensor.

[0103] Clause 20. The tool string of clause 17, wherein the tool string further includes a plug tool positioned in the downhole direction relative to the casing measuring sub.

[0104] The specific embodiments described above have been illustrated by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.

[0105] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function] . . . ” or “step for [perform]ing [a function] . . . ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Examples

Embodiment Construction

[0019]One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0020]When introducing elements of various embodime...

Claims

1. A measuring sub of a tool string, comprising:a casing reading system;a processor; anda hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising:receiving spatial data from the casing reading system; andstoring the spatial data associated with the casing locally to the measuring sub.

2. The measuring sub of claim 1, wherein the casing reading system includes an optical array.

3. The measuring sub of claim 1, wherein the casing reading system includes an induction sensor array.

4. The measuring sub of claim 1, wherein the spatial data includes visual data of the casing.

5. The measuring sub of claim 1, wherein the spatial data includes material data of the casing.

6. The measuring sub of claim 1, wherein the spatial data includes an aspect ratio of the casing.

7. The measuring sub of claim 1, wherein the spatial data includes perforation data of the casing.

8. The measuring sub of claim 1, wherein the spatial data includes thickness data of the casing.

9. The measuring sub of claim 1, wherein the spatial data includes a plurality of measurements associated with overlapping axial positions in the borehole.

10. The measuring sub of claim 1, wherein the instructions further cause the processor to analyze the spatial data to detect one or more properties associated with a casing of a borehole.

11. The measuring sub of claim 10, wherein the one or more properties associated with the casing are stored on the hardware storage device.

12. A method of measuring a casing property, the method comprising:providing a downhole sensor incorporated into a tool string;positioning the tool string in a downhole environment of a borehole;determining one or more casing properties of a casing using the downhole sensor; andrecording the one or more casing properties locally in the tool string.

13. The method of claim 12, wherein the tool string further includes a perforation tool, and further comprising:perforating the casing with the perforation tool;determining one or more perforation properties of a perforation of the casing using the downhole sensor; andrecording the one or more perforation properties locally in the tool string.

14. The method of claim 13, wherein perforating the casing and determining one or more perforation properties are performed in one trip of the tool string into the borehole.

15. The method of claim 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and measuring one or more perforation values while moving the downhole sensor in the uphole direction.

16. The method of claim 13, wherein determining one or more perforation properties of a perforation of the casing using the downhole sensor includes moving the downhole sensor in an uphole direction and stopping uphole movement of the downhole sensor while measuring one or more perforation values.

17. A tool string comprising:a perforation tool; anda casing measuring sub connected to the perforation tool in a downhole direction from the perforation tool, wherein the casing measuring sub includes:a casing reading system,a processor, anda hardware storage device having instructions stored thereon that, when executed by the processor, cause the processor to perform operations, comprising:receiving data from the casing reading system, andstoring the spatial data associated with the casing locally to the measuring sub.

18. The tool string of claim 17, wherein the casing reading system includes at least one optical sensor.

19. The tool string of claim 17, wherein the casing reading system includes at least one induction sensor.

20. The tool string of claim 17, wherein the tool string further includes a plug tool positioned in the downhole direction relative to the casing measuring sub.

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