Multi-Component Conformable Sensors for Downhole Imaging
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Solution Overview
Problem
Current downhole drilling operations face limitations in accurately measuring and identifying small features within wellbores due to the granularity of existing measurements, which can lead to issues such as crack and corrosion damage in casings, affecting the integrity and efficiency of hydrocarbon recovery.
Innovation Solution
The implementation of multi-component conformable sensors that can be positioned proximate to downhole elements, featuring planar sensors with tilted coils or antenna windings oriented in multiple directions, allowing for high-resolution, azimuthally sensitive measurements to improve visualization and identification of downhole elements, including pipes and boreholes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensors are used for downhole measurements, then device complexity is reduced, but measurement precision deteriorates due to inability to resolve small features
Solution Approach 1:
The sensor system is divided into multiple independent sensor components, each sensitive to specific azimuthal directions. Multiple tilted coil sensors are arranged at different orientations to collectively capture multi-component magnetic field information, enabling high-resolution imaging through segmented measurement approach
Solution Approach 2:
The patent introduces azimuthal sensitivity as an additional measurement dimension by tilting coil sensors at specific angles. This adds directional information to the measurements, transforming single-component measurements into multi-component measurements that resolve small features through enhanced dimensional data
2Loss of information
If conventional sensors are used, then device complexity is lower, but information completeness deteriorates due to limited granularity
Solution Approach 1:
The tilted coil sensor assembly serves multiple functions simultaneously: it measures magnetic field strength, determines azimuthal orientation, and resolves small features through multi-component detection. This multi-functional sensor design reduces information loss by capturing diverse physical parameters with a single integrated system
Solution Approach 2:
The patent introduces specialized signal processing and inversion algorithms as intermediary elements that transform raw multi-component sensor data into comprehensive downhole images. These computational intermediaries extract maximum information from the sensor measurements, completing the information chain between physical measurement and interpretable results
3Measurement precision
If multi-component conformable sensors are implemented, then measurement precision improves for small features, but device complexity increases due to multiple sensor components
Solution Approach 1:
The sensor assembly is designed with conformable, flexible materials that allow it to bend and conform to the curved surface of the wellbore or pipe. This curved geometry enables the multi-component sensors to maintain optimal orientation relative to the downhole structure, achieving high measurement precision while adapting to complex geometries
Solution Approach 2:
The patent employs flexible printed circuit boards and thin-film sensor technologies to create conformable sensor assemblies. These flexible substrates allow the multi-component sensors to be positioned precisely on curved surfaces, maintaining measurement accuracy while reducing the mechanical complexity of rigid mounting structures
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 solution enables high-resolution imaging and parameter determination of downhole elements, effectively identifying small features like cracks and corrosion, thereby enhancing the integrity and efficiency of hydrocarbon recovery operations by providing detailed visualization and accurate parameter measurement.
Implementation Method 1
a transmitter coupled to the first flexible material. A receiver may be coupled to the first flexible material, the receiver having at least two antenna windings positioned in different orientations
Implementation Method 2
generate an electromagnetic signal in a downhole element using the transmitter, and measure a response of the downhole element to the electromagnetic signal using the at least two antenna windings of the receiver
Data Source
AI summary
An example downhole tool incorporating aspects of the present disclosure may include a tool body and a first flexible material coupled to the tool body. A transmitter may be coupled to the first flexible material. A receiver may coupled to the first flexible material, with the receiver having at least two antenna windings positioned in different orientations. A control unit may be communicably coupled to the transmitter and the receiver, the control unit having a processor and a memory device coupled to the processor, the memory device containing a set of instruction that, when executed by the processor, cause the processor to generate an electromagnetic signal in a downhole element using the transmitter, and measure a response of the downhole element to the electromagnetic signal using the at least two antenna windings of the receiver.