Through Tubing Acoustic Imaging Pad Assembly

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Solution Overview

Problem

Current methods for inspecting the cement bond and formation adjacent to casing in wellbores require removing production tubing, which is time-consuming and costly, and existing downhole imaging devices face accuracy issues due to varying tubing positions.

Innovation Solution

A downhole imaging system that uses a pad assembly with an electroactive material, backing, and intervening layer to generate and sense acoustic signals, allowing for accurate imaging of the cement bond and casing without removing the production tubing by estimating distances and positions through the analysis of reflected signals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If production tubing is removed to inspect cement bond and casing, then inspection accuracy is improved, but inspection time and cost increase

Engineering Contradiction:

Improveinspection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces mechanical removal of tubing with an acoustic imaging system that uses acoustic waves to inspect cement bond and casing through the tubing wall, eliminating the need for physical tubing removal while maintaining inspection capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses acoustic waves as an intermediary to transmit inspection information through the tubing wall without direct contact or removal of the tubing, enabling non-intrusive inspection of the cement bond and casing

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If production tubing is removed to inspect cement bond and casing, then inspection accuracy is improved, but operational cost increases

Engineering Contradiction:

Improveinspection accuracyVSAvoidoperational cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the costly mechanical process of tubing removal with an acoustic imaging system that can inspect through the tubing wall, significantly reducing operational costs while maintaining inspection quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The acoustic imaging system allows the existing tubing to serve dual purposes: maintaining production flow while simultaneously enabling inspection functions, eliminating the need for separate tubing removal operations

Inventive Principle:

Principle #25Self-service

3Productivity

If downhole imaging devices are deployed through production tubing, then inspection can be performed without removing tubing, but imaging accuracy deteriorates due to varying tubing position

Engineering Contradiction:

Improveinspection efficiencyVSAvoidimaging accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent incorporates a positioning system that provides feedback on tubing position and orientation, allowing the acoustic imaging system to compensate for varying positions and maintain accurate imaging of the cement bond and casing

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent adjusts acoustic signal parameters such as frequency, amplitude, and transmission angle based on detected tubing position variations, maintaining optimal imaging conditions despite changes in tubing placement

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient and accurate imaging of the cement bond and casing without disrupting the production tubing, improving inspection efficiency and reducing costs by providing precise information on cement bond integrity and casing positions.

Implementation Method 1

forming an acoustic transmitter by contacting the pad assembly with the inner tubular, generating a vibration with the acoustic transmitter to form a transmitted signal

Methodology Applied

Scientific EffectElectroactive material vibration: Electroactive Polymer

Implementation Method 2

generating a vibration with the acoustic transmitter to form a transmitted signal that propagates radially outward from the inner tubular

Methodology Applied

Scientific EffectAcoustic wave propagation: Sound

Implementation Method 3

using the pad assembly to sense a reflected signal that is formed by the transmitted signal reflecting from the outer tubular

Methodology Applied

Scientific EffectAcoustic reflection: Reflection

Implementation Method 4

using the pad assembly to sense a reflected signal that is formed by the transmitted signal reflecting from the outer tubular

Methodology Applied

Scientific EffectAcoustic sensing: Sound

Data Source

PatentUS11378709B2Through tubing acoustic imaging

Publication Date: 2022.07.05 BAKER HUGHES CO

AI summary

An outer tubular is imaged by a pad assembly disposed within an inner tubular inserted within the outer tubular. The pad assembly is in contact with the inner tubular, and includes an acoustic pressure source, a backing mounted to a side of the acoustic pressure source, and an intervening layer between the acoustic pressure source and inner tubular. Signals generated by the pad assembly propagate radially outward from the inner tubular and reflect from the outer tubular. The generated and reflected signals travel through a medium between the inner and outer tubulars. An estimate of the distance between the inner and outer tubulars is based on the time from generation of the signal to when the reflected signal is sensed.