Downhole Cement Plug CCL Location Accuracy

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Solution Overview

Problem

Conventional methods for determining the volume of displacement fluid in primary cementing are inaccurate due to uncertainties in casing inner diameter and fluid compressibility, leading to risks of under or over displacement, which can jeopardize the success of the cementing process.

Innovation Solution

A downhole cement plug system that includes a casing collar locator (CCL) to generate signals indicative of casing collars, a controller to output distinct frequency signals, and a signal generator to transmit these signals to the surface, allowing for accurate location determination of the cement plug within the wellbore.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods are used to determine displacement fluid volume from casing ID and length, then the calculation is simple, but the measurement precision deteriorates due to uncertainties in casing ID uniformity and fluid compressibility

Engineering Contradiction:
Improvesimplicity of calculationVSAvoidaccuracy of displacement fluid volume
Core Design Contradiction:
Ease of manufactureVSMeasurement precision

Solution Approach 1:

The patent replaces the conventional mechanical calculation method (based on casing ID and length assumptions) with an acoustic signal transmission method. The downhole tool transmits acoustic signals through the displacement fluid to the surface, where the two-way travel time is measured and converted to depth information. This substitution eliminates the need for manual calculations and assumptions about casing uniformity, providing direct empirical measurement of the tool's position and thus the accurate displacement fluid volume required.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If acoustic signal transmission is used to locate the downhole tool, then the location precision is improved, but the device complexity increases due to additional components like transducers and signal processors

Engineering Contradiction:
Improveaccuracy of cement plug locationVSAvoidcomplexity of locating system
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses the displacement fluid itself as an intermediary medium to transmit acoustic signals between the downhole tool and the surface. Instead of requiring complex wireless communication systems or physical connections, the system leverages the existing displacement fluid in the wellbore as the transmission medium. This approach achieves accurate location measurement while minimizing additional device complexity, as the fluid is already present and serves a dual purpose: displacement function and signal transmission medium.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Reliability

If real-time location monitoring is implemented, then the reliability of cementing operation is improved, but the energy consumption increases due to continuous signal transmission and processing

Engineering Contradiction:
Improvesuccess rate of primary cementingVSAvoidenergy consumption of downhole tool
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent implements periodic signal transmission rather than continuous transmission. The downhole tool transmits acoustic signals at specific intervals or at key operational moments (such as when the tool reaches certain depths or during critical cementing phases). This periodic approach provides sufficient real-time monitoring data to ensure cementing reliability while significantly reducing the energy consumption compared to continuous transmission, as the tool only activates its transducer when needed.

Inventive Principle:
Principle #19Periodic action

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

This system enables precise location and speed determination of the cement plug, reducing errors in displacement fluid volume and enhancing the success of primary cementing operations by providing real-time data on casing collar positions and plug movement.

Implementation Method 1

a casing collar locator (CCL) operable to generate signals indicative of casing collars on a downhole casing string of a wellbore system

Methodology Applied
Scientific EffectElectromagnetic signal transmission: Electromagnetic Induction

Data Source

PatentUS10711593B2Locating a downhole tool in a wellbore
Publication Date: 2020.07.14 HALLIBURTON ENERGY SERVICES INC
  • US10711593B2 patent drawing
  • US10711593B2 patent drawing
  • US10711593B2 patent drawing

AI summary

A downhole cement plug includes a casing collar locator (CCL) operable to generate signals indicative of casing collars on a downhole casing string of a wellbore system; a controller communicably coupled to the CCL to output a plurality of distinct frequency signals based on the signals from the casing collar locator; and a signal generator communicably coupled to the controller to receive the plurality of distinct frequency signals from the controller and transmit the plurality of distinct frequency signals to a terranean surface through a portion of a wellbore system.