Magnetic Sensor Assembly Non-Flat Plug Cement Slurry Detection
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Solution Overview
Problem
Current subterranean well operations, particularly reverse cementing, face challenges in accurately detecting cement slurry presence and concentration due to the lack of effective sensors that can withstand hostile environments and provide real-time feedback for valve activation.
Innovation Solution
A low-cost magnetic permeability sensing apparatus is introduced, comprising a magnet and magnetic sensor, which detects the presence and concentration of cement slurry by measuring magnetic permeability, allowing for precise valve control during reverse cementing operations. This apparatus includes a non-flat shape plug to enhance magnetic field detection and flow-induced force, enabling accurate measurement of cementing fluids with varying magnetic permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic sensor is used to detect cement slurry presence, then real-time detection capability is improved, but the sensor must withstand hostile subterranean environments which increases device complexity
Solution Approach 1:
The sensor assembly is divided into separate functional components: a magnet source, a magnetic sensor, and a non-flat plug. This segmentation allows each component to be optimized independently for its specific function while reducing overall complexity of the assembly design and manufacturing process.
Solution Approach 2:
A non-flat plug is introduced as an intermediary element between the magnet source and the cement slurry. This plug enhances the magnetic field detection capability and flow-induced force without requiring the sensor itself to directly contact the hostile environment, thus improving detection accuracy while protecting the sensor.
2Measurement precision
If a non-flat shape plug is used to enhance magnetic field detection, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The plug is designed with a non-flat curved surface (spheroidal or domed shape) instead of a flat surface. This curvature enhances the magnetic field detection accuracy and flow-induced force generation. The curved geometry can be manufactured using standard molding or machining processes, balancing improved measurement precision with reasonable manufacturing complexity.
3Measurement precision
If magnetic permeability sensing is used to detect cement slurry concentration, then measurement precision is improved, but the system requires additional components increasing device complexity
Solution Approach 1:
The magnet source and magnetic sensor are combined into a single integrated sensing apparatus, along with the non-flat plug. This merging of components achieves magnetic permeability sensing for slurry concentration detection while minimizing overall device complexity through compact integration rather than separate distributed components.
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
The solution enables reliable detection of cement slurry presence and concentration, allowing for timely valve activation, thus preventing cement from ascending the wellbore and ensuring efficient cementing operations, even in hostile subterranean conditions.
Implementation Method 1
detects the presence and concentration of cement slurry by measuring magnetic permeability
Implementation Method 2
A low-cost magnetic permeability sensing apparatus is introduced, comprising a magnet and magnetic sensor
Implementation Method 3
This apparatus includes a non-flat shape plug to enhance magnetic field detection and flow-induced force
Data Source
AI summary
Disclosed herein are embodiments of a sensor assembly apparatus, system, and method. In one embodiment, an apparatus comprises a sensor assembly adapted to be integrated into a casing to be positioned in a wellbore, the sensor assembly comprising a housing; a magnet located within the housing; a magnetic sensor located within the housing to measure a magnetic measurement change resulting from a force between the magnet and magnetic particles flowing with a cement slurry inside the casing from a reverse cementing; and a sensor plug having a side with a non-flat shape that is to be in contact with the slurry flowing in the casing of the wellbore; a processor communicatively coupled to the magnetic sensor and configured to determine whether the magnetic measurement change exceeds a magnetic threshold; and determine that the slurry is flowing back up internal to the casing at or beyond a location in the wellbore.