Encapsulated Phased Array Segment for Downhole Acoustic Logging
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Solution Overview
Problem
Existing acoustic pulse-echo imaging tools for borehole logging face challenges in precision and durability due to exposure to harsh borehole conditions, particularly during drilling operations, which affects the accuracy and reliability of acoustic measurements.
Innovation Solution
The use of self-contained convex linear phased array modules with a rigid shell and piezoelectric component arrays, configured to withstand vibrations and shocks, and capable of beam steering and focal depth adjustment, allows for precise acoustic measurements and continuous circumferential scanning of the borehole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acoustic imaging tools are used in harsh borehole conditions, then borehole logging operations can be performed, but measurement precision deteriorates due to vibrations and shocks
Solution Approach 1:
The acoustic array is divided into multiple self-contained convex linear phased array modules that can be circumferentially arrayed about the tool. Each module is independently encapsulated in a rigid shell, allowing the system to maintain functionality while reducing the impact of vibrations and shocks on individual elements.
Solution Approach 2:
Each piezoelectric component array is enclosed within a rigid shell forming a sealed compartment before deployment. This pre-protection approach shields the sensitive acoustic components from vibrations, shocks, and borehole fluids, ensuring measurement precision is maintained in harsh downhole conditions.
2Reliability
If piezoelectric component arrays are exposed to borehole fluids, then acoustic measurements can be taken, but reliability deteriorates due to damage from fluids and debris
Solution Approach 1:
Each piezoelectric component array is enclosed within a rigid shell forming a sealed compartment before deployment. This pre-protection approach shields the sensitive acoustic components from vibrations, shocks, and borehole fluids, ensuring measurement precision is maintained in harsh downhole conditions.
Solution Approach 2:
The rigid shell enclosure acts as a protective barrier between the piezoelectric components and the harsh borehole environment. This encapsulation strategy allows the acoustic tool to reliably operate while exposed to borehole fluids and debris without compromising the integrity of the piezoelectric elements.
3Measurement precision
If multiple phased array modules are arrayed circumferentially, then continuous circumferential measurement is achieved, but device complexity increases
Solution Approach 1:
Each convex linear phased array module is designed as a self-contained unit that can independently perform acoustic measurements. By circumferentially arraying multiple identical modules, the system achieves continuous circumferential coverage while using standardized, interchangeable components that simplify manufacturing and maintenance despite the increased number of elements.
Solution Approach 2:
The acoustic array is divided into multiple self-contained convex linear phased array modules that can be circumferentially arrayed about the tool. Each module is independently encapsulated in a rigid shell, allowing the system to maintain functionality while reducing the impact of vibrations and shocks on individual elements.
4Reliability
If self-contained modules with rigid shells are used, then protection from vibrations and shocks is improved, but manufacturing complexity increases
Solution Approach 1:
The acoustic array is divided into multiple self-contained convex linear phased array modules that can be circumferentially arrayed about the tool. Each module is independently encapsulated in a rigid shell, allowing the system to maintain functionality while reducing the impact of vibrations and shocks on individual elements.
Solution Approach 2:
The piezoelectric component arrays are nested within rigid shell enclosures, creating a hierarchical protective structure. This nesting approach allows the sensitive components to be protected within compact, standardized modules that can be easily manufactured and assembled onto the acoustic tool.
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 configuration enhances the accuracy and reliability of borehole parameter estimation, including size, shape, acoustic reflection strength, and geometry, while preventing damage from borehole fluids and debris, enabling more effective logging operations.
Implementation Method 1
a piezoelectric component array
Implementation Method 2
measuring a returning echo of the previously emitted acoustic pulse which is reflected off the borehole wall
Implementation Method 3
convex linear phased array module... capable of beam steering and focal depth adjustment
Data Source
AI summary
Systems, devices, and methods for estimating a value of a parameter of interest of an earth formation intersected by a borehole. Methods include conveying a carrier in the borehole having disposed thereon an acoustic imaging tool including at least one convex linear phased array module, each of the at least one module comprising a rigid shell forming a compartment containing a piezoelectric component array; using the acoustic imaging tool to take acoustic measurements of the borehole; and using the acoustic measurements to estimate at least one parameter of interest. Each module may be self-contained. The tool may include a plurality of modules circumferentially arrayed about a portion of the acoustic tool. Methods include individually removing one selected module from the acoustic tool. Methods may include selecting an outer tool diameter the same as an inner borehole diameter borehole and selecting a maximum number of modules fitting the outer tool diameter.