Minimal Sensor Collars for Downhole Measurement Cost Reduction
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Solution Overview
Problem
The high cost of implementing downhole sensors in borehole drilling operations limits the efficiency and cost-effectiveness of collecting subterranean formation measurements, as existing systems often require expensive electronics and precise placement of transmitters and receivers.
Innovation Solution
A sensor collar system is introduced, where a main collar with electromagnetic electronics is mechanically and communicatively coupled to a drill string, and an attachable collar with minimal or no electronics is used to collect measurements, allowing for flexible transmitter-receiver spacing and orientation, reducing overall system costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional downhole sensors with complete electronics are used in each collar, then measurement capability is improved, but system cost increases significantly
Solution Approach 1:
The sensor system is divided into two functional segments: a main collar containing the electromagnetic transmitter and control electronics, and one or more passive sensor collars containing only receiver elements. This segmentation allows the expensive electronic components to be concentrated in a single unit while multiple simpler collars perform sensing functions, significantly reducing overall system cost while maintaining measurement capability.
Solution Approach 2:
The patent introduces passive sensor collars as intermediary elements that receive electromagnetic signals from the main collar and transmit measurement data back to the surface without requiring their own power sources or complex electronics. These passive collars act as mediators between the active transmitter and the measurement system, enabling cost-effective distributed sensing along the drill string.
2Device complexity
If transmitters and receivers are placed close together in the same collar, then device complexity is reduced, but measurement fidelity and depth are limited
Solution Approach 1:
The patent extends the sensor system along the longitudinal dimension of the drill string by placing multiple passive sensor collars at different depths. This dimensional extension allows electromagnetic signals to propagate over longer distances along the drill string, enabling measurements at greater depths and improving measurement fidelity without increasing the complexity of individual collar units.
Solution Approach 2:
The system allows for dynamic configuration of transmitter-receiver spacing by selectively activating different passive sensor collars based on drilling depth and formation characteristics. This dynamic adaptability enables optimization of measurement fidelity for different geological conditions while maintaining system simplicity through a standardized modular collar design.
3Manufacturing precision
If fixed transmitter-receiver spacing is used, then manufacturing precision requirements are reduced, but adaptability to different measurement needs is limited
Solution Approach 1:
The modular collar design with multiple passive sensor units allows the system to dynamically adjust transmitter-receiver spacing by selecting which collars are activated. This dynamic configuration capability provides adaptability to different measurement requirements and formation conditions while maintaining simple manufacturing specifications for each standardized collar unit.
Solution Approach 2:
Each passive sensor collar is designed as a universal module that can function as a receiver at various positions along the drill string. This universality allows the same collar design to be used in multiple configurations with different spacing arrangements, providing measurement flexibility without requiring custom-manufactured collars for each specific spacing requirement.
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 enables advanced measurement collection with reduced costs by allowing for adjustable transmitter-receiver spacing and orientation, enhancing measurement fidelity and depth, while maintaining system flexibility and simplicity.
Implementation Method 1
the first portion of the electromagnetic system is at least one receiver to detect an electromagnetic energy or at least one transmitter to transmit the electromagnetic energy
Data Source
AI summary
This disclosure presents an apparatus and system for lowering the cost of implementing a downhole sensor system using attachable collars. In some aspects, the attachable collar includes a transmitter component, while supporting electronics are included with a main collar, thereby reducing the cost of the attachable collar. The supporting electronics can send a transmission signal, a control signal, a synchronization clock signal, a selected transmission frequency, a sensor orientation and selection, and other instructions to the transmitter in the attachable collar. The receiver in the main collar can receive the output, as reflected by the subterranean formation, and transform the output to subterranean formation evaluation measurements. The measurements can be communicated to other systems. In some aspects, the attachable collar can include the receiver and the main collar can include the transmitter. In some aspects, additional attachable collars can be included on the drill string to increase the transmitter-receiver spacing.