Downhole Casing Connection Inspection with Radial Ultrasound Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for evaluating the quality of casing connections in oil and gas wellbores are limited by the lack of access for ultrasound tools after installation, as they cannot be deployed around the outside of the casing, and there is no effective way to locate connections within kilometers of casings in use, which are subjected to high temperatures, pressures, and mechanical stress.
Innovation Solution
A method and system for in-situ inspection of casing connections using an imaging tool with a radial array of ultrasound transducers that can be deployed through the casing, analyzing ultrasound images to detect features of casing connectors, locate a sealing band, and determine connection quality, including mechanical strength and sealing integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ultrasound testing is performed in the factory using external access and coupling gel, then connection quality can be evaluated with high precision, but the method cannot be applied once casings are installed in the wellbore due to lack of external access
Solution Approach 1:
The imaging tool is deployed inside the casing string, nesting the inspection device within the object being inspected. This allows ultrasound transducers to contact the inner surface of casings from the interior, enabling connection quality evaluation after installation without requiring external access to the casing exterior.
Solution Approach 2:
Instead of accessing the outer surface of casings as in traditional ultrasound testing, the method inverts the approach by deploying the imaging tool inside the casing to inspect the inner surface. This reversal enables inspection in the installed state where external access is unavailable.
2Reliability
If casings are inspected after installation in the wellbore, then connection quality can be evaluated in-service under actual operating conditions, but there is no effective way to locate connections within kilometers of casings
Solution Approach 1:
The system performs preliminary detection of connection features by analyzing ultrasound reflections from threading patterns, torque shoulders, and dope relief channels before attempting to locate and evaluate specific connections. This preliminary scanning enables the tool to identify and navigate to connection locations automatically during its traverse through the casing string.
Solution Approach 2:
The system uses characteristic ultrasound reflections from connection features (threading patterns, torque shoulders, dope relief channels) as intermediaries to detect and locate connections. These reflected signals serve as markers that enable the tool to identify connection positions and evaluate their quality without requiring external location information.
3Adaptability or versatility
If a radial array of ultrasound transducers is deployed through the casing, then connection quality can be evaluated in-situ, but the device complexity increases compared to simple external ultrasound testing
Solution Approach 1:
The imaging tool integrates multiple functions including ultrasound transmission, reception, signal processing, and connection quality evaluation into a single deployable device. The radial array of transducers serves multiple purposes: detecting connection features, locating connections, and evaluating sealing quality, thereby justifying the increased complexity through multi-functionality.
Solution Approach 2:
The system automatically processes ultrasound signals to detect connection features, locate connections, and evaluate quality without requiring external intervention. The tool self-navigates through the casing string, automatically identifies connection positions based on reflected signals, and performs quality assessment, reducing the need for complex external positioning and evaluation systems.
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 the evaluation of casing connections in real-time while in the well, providing metrics on sealing contact pressure, mechanical strength, and leak estimation, thereby identifying potential failure modes and ensuring long-term integrity.
Implementation Method 1
imaging the casing with a radial array of ultrasound transducers to create an ultrasound image
Implementation Method 2
create an ultrasound image by emitting ultrasound waves into the casing and creating images based on reflected sound
Data Source
AI summary
A method and system for inspecting casings in a wellbore to determine a mechanical or sealing quality of casing connections. Casing connections may become mechanically weak or start to leak after some period of use in harsh conditions. A radial array of ultrasound transducers images the casing in-situ to create an ultrasound image, which is analyzed to detect the casing connector then analyzed a sealing band of the connector. Machine learning and image processing methods may be used to analyze the images.