Gimbaled Ultrasonic Sensor Array for Downhole Geometry Reconstruction
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Solution Overview
Problem
Conventional downhole navigation tools for fossil fuel exploration face limitations in dynamic range and effectiveness, particularly in hostile multiphase flow regimes, due to shortcomings in sensor arrangements and data processing methods.
Innovation Solution
The use of a dense array of ultrasonic transducers with multiple actuators and sensors, coupled with a gimbaled joint and electronic control unit, enables comprehensive scanning and data transmission for improved downhole geometry reconstruction and feature detection, employing pulse compression and matched filter techniques to enhance signal-to-noise ratio and dynamic range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensor arrangements are used in downhole navigation tools, then the device complexity is reduced, but the measurement precision and dynamic range are limited
Solution Approach 1:
The sensor head is divided into multiple sensor elements arranged in arrays, with each element capable of independent measurement. This segmentation allows the system to achieve higher measurement precision through multiple measurement points while managing complexity through modular design of the sensor elements.
Solution Approach 2:
The patent transitions from conventional single-point or limited-point sensing to multi-dimensional arrays of sensor elements that can measure in multiple directions and positions simultaneously. This dimensional expansion enables comprehensive downhole geometry reconstruction with improved accuracy.
2Reliability
If conventional sensing methods are used, then the device simplicity is maintained, but the effectiveness in hostile multiphase flow regimes is reduced
Solution Approach 1:
Multiple sensor elements are distributed throughout the sensor head, allowing the system to maintain reliable measurements in hostile multiphase flow regimes by having redundant measurement points that can compensate for individual element failures or performance degradation in difficult conditions.
Solution Approach 2:
The system processes signals from multiple sensor elements and uses correlation techniques to identify and compensate for noise and interference from multiphase flow, providing feedback-based signal enhancement that maintains reliability in challenging environments.
3Measurement precision
If a dense array of ultrasonic transducers is deployed, then the measurement precision and dynamic range are improved, but the device complexity and data processing requirements increase
Solution Approach 1:
The dense array of ultrasonic transducers is organized into modular sensor elements, where each element contains multiple actuators and sensors that can be controlled and processed independently. This segmentation enables high measurement precision while managing device complexity through structured organization of the transducer elements.
Solution Approach 2:
The electronic control unit pre-configures the dense transducer array with specific actuation patterns and signal processing algorithms before deployment. This preliminary configuration optimizes the array's performance for specific measurement tasks, enabling high precision feature detection while reducing the complexity of real-time control and data processing.
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 approach significantly improves the ability to accurately reconstruct borehole geometry and detect features, even in complex and turbulent environments, by increasing resolution and precision through comprehensive data collection and processing, thereby enhancing navigation and data accuracy.
Implementation Method 1
The electronic control unit is configured to trigger the actuator elements of the array to transmit ultrasonic energy in the form of modulated pulses
Implementation Method 2
employing pulse compression and matched filter techniques to enhance signal-to-noise ratio and dynamic range
Implementation Method 3
The array is positioned on a pivotable tip of the downhole apparatus. In a first embodiment, the sensor head is gimbaled, enabling the sensor head to be maneuvered
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
An apparatus for detecting and determining geometric features inside a borehole comprises a body section coupled to and deployable in the borehole by a conveyor, a head section having a first end pivotably coupled to the body section via a joint and a second end having an array of ultrasonic transducers. The array of transducers comprises, for example, a multiplicity of individual actuator elements and a multiplicity of individual sensor elements. An electronic control unit controls the timing of emission of ultrasonic radiation from the actuator elements of the array, receives signals generated by the sensor elements of the array, and controls movement of the head section via an actuator coupled to the joint. A method for reconstructing a geometry and detecting and identifying features in a borehole is also provided.