Multi-layer conformable sensors for downhole casing inspection
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Solution Overview
Problem
Current downhole drilling and hydrocarbon production operations face limitations in measuring downhole elements due to low granularity and interference from casings, making it difficult to identify small features and assess casing damage accurately.
Innovation Solution
The implementation of multi-layer conformable sensors that use stacked antenna arrays with flexible materials to generate high-resolution, azimuthally sensitive measurements by transmitting electromagnetic signals and measuring responses, allowing for detailed imaging of downhole elements, including pipes, cement layers, and formations, even in multi-casing environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional single-layer sensors are used for downhole measurements, then the device complexity is low, but the measurement precision is insufficient to identify small features
Solution Approach 1:
The sensor is divided into multiple stacked layers, with each layer contributing to different aspects of the measurement. This segmentation allows the system to achieve high-resolution measurements by combining data from multiple layers, thereby identifying small features that single-layer sensors cannot detect.
Solution Approach 2:
The patent transitions from a single-layer sensor to a multi-layer stacked sensor array, adding the vertical dimension (layer stacking) to the measurement system. This dimensional change enables azimuthally sensitive measurements and high-resolution imaging of downhole elements by collecting data from multiple spatial positions simultaneously.
2Reliability
If conventional sensors are used in multi-casing environments, then the device complexity remains simple, but the ability to measure through casing interference is insufficient
Solution Approach 1:
The multi-layer sensor structure segments the measurement function across multiple layers, allowing each layer to contribute to penetrating different depths through the casing. This enables reliable assessment of casing integrity and detection of external features despite the presence of multiple casings.
Solution Approach 2:
By stacking sensors in multiple layers, the system adds vertical dimensionality to overcome the horizontal barrier of casings. This multi-layer configuration enables electromagnetic signals to penetrate through casings and accurately measure downhole elements, improving reliability in multi-casing environments.
3Measurement precision
If high-resolution measurements are achieved through multi-layer sensors, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The sensor system is segmented into multiple functional layers, where each layer is optimized for specific measurement tasks. This segmentation achieves high measurement precision through the combined data from multiple layers while maintaining manageable complexity through modular design.
Solution Approach 2:
The patent uses vertical stacking of sensor layers to achieve high-resolution measurements without proportionally increasing lateral device complexity. The multi-layer configuration provides azimuthally sensitive measurements and high-resolution imaging by utilizing the vertical dimension efficiently.
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 solution provides high-resolution measurements that can identify small features and assess casing integrity, enabling accurate visualization and parameter determination of downhole elements, such as cracks and corrosion, improving the monitoring and maintenance of downhole conditions.
Implementation Method 1
a transmitter of the multi-layer sensor generates an electromagnetic signal
Implementation Method 2
a receiver of the multi-layer sensor measures a response of the formation to the electromagnetic signal
Data Source
AI summary
An example downhole tool includes a tool body and a multi-layer sensor coupled to the tool body. The multi-layer sensor may include a first transmitter coupled to a first conformable element and a first receiver coupled to a second conformable element. One of the first conformable element and the second conformable element may overlay the other of the first conformable element and the second conformable element.