Localized High-Resolution Tubular Imaging via Dual-Sensor Segmentation
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Solution Overview
Problem
Current ultrasound tools for inspecting fluid-carrying conduits face challenges in logging speed due to the need for high-resolution imaging of long tubulars, which limits their ability to efficiently detect localized features such as perforations or leaks, requiring extensive imaging of the entire length for visualization.
Innovation Solution
A downhole tool and method that separates the process into low-resolution scanning for candidate feature detection and high-resolution imaging of localized areas using a phased array ultrasound sensor and a camera, allowing for real-time or offline processing to visualize tubular and feature data efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-resolution imaging is performed along the entire tubular length, then measurement precision is improved, but productivity deteriorates due to limited logging speed
Solution Approach 1:
The patent applies local quality by performing high-resolution imaging only at localized areas of interest rather than uniformly across the entire tubular. The system first performs low-resolution scanning to identify candidate features, then concentrates high-resolution imaging resources only on those specific locations, making the measurement precision non-uniform and adapted to actual needs.
Solution Approach 2:
The inspection process is segmented into two distinct phases: a first low-resolution scanning pass to identify candidate localized features, and a second high-resolution imaging pass focused only on those identified candidates. This segmentation allows the system to achieve high measurement precision where needed while maintaining high productivity overall.
2Reliability
If the entire tubular is imaged in high-resolution, then reliability of defect detection is improved, but loss of time increases due to extensive data processing
Solution Approach 1:
The system performs preliminary low-resolution scanning before high-resolution imaging to pre-identify candidate features. This preliminary action filters out large portions of the tubular that do not contain defects, so that subsequent high-resolution imaging and processing are performed only on relevant sections, reducing total processing time while maintaining detection reliability.
Solution Approach 2:
Instead of performing full high-resolution imaging on the entire tubular, the system applies high-resolution imaging only partially to candidate areas identified in the first pass. This partial action is sufficient to detect defects reliably while avoiding the excessive time cost of processing the entire tubular at high resolution.
3Measurement precision
If high-resolution imaging is performed on the entire tubular, then measurement precision is improved, but device complexity increases due to memory and processing requirements
Solution Approach 1:
The patent reduces device complexity by applying high measurement precision locally only to candidate areas rather than uniformly across the entire tubular. The memory and processing resources are concentrated on storing and analyzing high-resolution data only for localized features, rather than managing terabytes of full-length high-resolution imagery.
Solution Approach 2:
The imaging process is segmented into low-resolution scanning and high-resolution imaging phases, with different data storage requirements for each. This segmentation allows the system to use modest memory resources for the majority of the tubular (low-resolution data) while allocating higher resources only to candidate areas (high-resolution data), greatly reducing overall device complexity.
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
Enables high-resolution imaging of localized features while maintaining high-speed logging, reducing the need for extensive data storage and processing of the entire tubular length, thereby improving inspection efficiency and accuracy.
Implementation Method 1
a phased array ultrasound sensor
Implementation Method 2
The reflected waves are received by the same elements and the pulse-echo time of the waves are used to deduce the distances
Implementation Method 3
the pulse-echo time of the waves are used to deduce the distances to the inner and outer walls
Implementation Method 4
imaging the tubular with the camera to generate optical images
Data Source
AI summary
A device and method used to image wells and other fluid-carrying tubulars having localized features of interest. The device scans large areas of the tubular first in a low-resolution mode using an ultrasound sensor and in a high-resolution mode using a camera, then identifies areas that contain those localized features with some probability. The device images are stored for further image processing. The two sensors are axially spaced-apart on the device. A computer remote from the imaging device renders a visualization of the tubular and localized features using the optical and ultrasound images.