Sensor Roller Logging Module Borehole Contact
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Solution Overview
Problem
Traditional wireline logging sensors and logging while drilling (LWD) sensors face challenges such as poor contact with the formation, poor data resolution, and high maintenance due to the rough and complex borehole environment, particularly when deployed on pad devices or flappers.
Innovation Solution
A logging module configuration using sensor rollers mounted on a tool body, where the rollers can extend and rotate to maintain contact with the borehole wall, equipped with wear fins for protection and sensors for data collection, and an optimized design generated using a neural network based on historical data for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional logging sensors are mounted on pad devices or flappers, then the sensors can be deployed in the borehole, but they experience poor contact with the formation and poor data resolution
Solution Approach 1:
The patent employs rollers instead of flat pads to contact the borehole wall. The cylindrical shape of the rollers allows them to naturally conform to the curved borehole surface, ensuring consistent contact between the sensors mounted on the roller surface and the formation. This curvature-based design resolves the contact inconsistency problem that plagues traditional pad devices.
Solution Approach 2:
The rollers are designed to rotate as they contact the borehole wall, transforming the static contact of traditional pads into dynamic rolling contact. This rotation ensures that different portions of the roller surface sequentially contact the formation, maintaining continuous and consistent sensor contact despite borehole irregularities, thereby improving both contact reliability and data resolution.
2Productivity
If logging sensors are deployed on pad devices in the rough borehole environment, then they can collect data, but they suffer from high maintenance due to damage to the sensors
Solution Approach 1:
The patent incorporates protective features into the roller design before deployment. The rollers are designed with robust structures that can withstand the rough borehole environment, and sensors are mounted on the rotating roller surface rather than directly on the tool body, providing a buffer against direct impacts and reducing damage risk, thereby lowering maintenance frequency.
Solution Approach 2:
The rotating roller design allows the sensors to self-clean or self-adjust during operation. As the roller rotates, it naturally sheds debris and maintains optimal contact with the formation without requiring external intervention or frequent maintenance, enabling continuous data collection in harsh environments.
3Device complexity
If sensors are mounted directly on the tool body, then the structure is simple, but the contact with the formation is poor and data resolution is reduced
Solution Approach 1:
By mounting sensors on the cylindrical surface of rotating rollers rather than directly on the flat tool body, the patent achieves better formation contact. The curved roller surface naturally conforms to the borehole wall geometry, improving sensor contact quality and data resolution while adding only a simple rotational mounting mechanism.
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 sensor roller configuration enhances data resolution and reduces maintenance by ensuring consistent contact with the borehole surface, improving data quality and reducing damage, while the neural network optimization enhances the logging module's design for better performance in challenging environments.
Implementation Method 1
mount the logging sensors on a tool body that is decentered using accessories such as bow spring or offset subs, so that the sensors contact with the formation under gravity
Implementation Method 2
mounting the at least one sensor roller into a compressible mounting assembly provided in the tool body
Data Source
AI summary
A method for configuring a logging module for logging sensors deployment based on a sensing data acquisition objective includes selecting a tool body, selecting at least one type of sensor, and selecting at least one type of roller. The method also includes incorporating the at least one selected type of sensor onto the at least one selected type of roller to provide at least one sensor roller, and mounting the at least one sensor roller into a compressible mounting assembly provided in the tool body to provide the logging module.