Detachable Fiber Optic Sensor for Cement Plug Positioning
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Solution Overview
Problem
Existing wellbore cementing processes face challenges in accurately tracking the location of cement plugs and detecting cement bond integrity due to small pressure variations, which can lead to errors and damage during the cementing operation.
Innovation Solution
A fiber optic telemetry system is employed, utilizing a sensor module with a magnetic pickup coil, piezoelectric sensor, and light source coupled to a fiber optic cable, allowing for real-time measurement and communication of the cement plug's position and cement bond status during both the run-in and pull-out phases, enabling precise monitoring and reducing the need for multiple trips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure variations are used to determine the location of cement plugs, then the location can be tracked, but the pressure variations are small and may not be detected or may be incorrectly interpreted
Solution Approach 1:
The patent replaces the mechanical pressure-based detection system with an optical sensing system using fiber optic cables. The fiber optic sensor detects the position of the cement plug by measuring optical properties (such as light reflection or transmission changes) rather than relying on small pressure variations, thereby achieving both high measurement precision and reliable detection.
Solution Approach 2:
The fiber optic cable acts as an intermediary between the cement plug and the surface measurement system. It transmits optical signals from the downhole environment to the surface, enabling accurate and reliable location tracking without being affected by the limitations of direct pressure measurement.
2Loss of information
If multiple trips are made to obtain well completion data, then comprehensive data can be collected, but downtime and resource allocation are increased
Solution Approach 1:
The fiber optic sensor system enables continuous monitoring of the cement plug position and well completion data throughout the entire cementing operation in a single trip. The sensor remains active during the run-in phase, cementing operation, and pull-out phase, eliminating the need for multiple trips to collect comprehensive data and thereby reducing downtime.
Solution Approach 2:
The sensor module is installed on the cement plug before the cementing operation begins. This preliminary setup allows data collection to start immediately during the run-in phase, rather than requiring separate trips after the operation to gather completion data.
3Productivity
If a detachable sensor module is used, then the sensor can be retrieved after use, but the coupling and decoupling mechanisms add device complexity
Solution Approach 1:
The sensor module is designed as a detachable unit that can be separated from the cement plug after completing its measurement function. This extraction of the sensing function from the permanent tooling allows the sensor to be retrieved and reused, improving productivity while the modular design keeps the coupling mechanism relatively simple.
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 enhances the accuracy of cement placement, reduces the risk of errors, and increases well integrity by providing early well completion data, thereby optimizing resource allocation and minimizing downtime and well log risks.
Implementation Method 1
The sensor module can be, or include, a magnetic pickup coil that can detect a disturbance or change in a magnetic field
Implementation Method 2
a piezoelectric sensor
Implementation Method 3
The light source can be coupled to a fiber optic cable that can extend to the surface. The fiber optic cable can transmit the pulse of light to a processing device
Data Source
AI summary
A sensor module can be used to make measurements during a single trip into and out of a wellbore in connection with a cement operation. The sensor module can include a detachment mechanism to detachably couple to a cement dart. The sensor module can also include a sensor to make measurements in a run-in-hole configuration prior to detaching from the cement dart and in a come-out-of-hole configuration subsequent to detaching from the cement dart in a wellbore. The sensor module can also include a transceiver to transmit the measurements to a processing device via a communication medium and to receive commands from the processing device via the communication medium.