Wellbore Mechanical Caliper With Pressure-Activated Diameter Sensing
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Solution Overview
Problem
Current mechanical calipers require an additional wireline trip to measure wellbore diameter, which prolongs the drilling operation time and cost due to wellbore instability causing irregularities in diameter estimation.
Innovation Solution
A caliper tool installed on a wireline assembly that measures wellbore diameter during Pull Out of Hole (POOH) operations, using measurement bands and electromagnetic sensors to calculate diameter without additional trips, activated by a fluid-induced actuating mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current mechanical calipers are used to measure wellbore diameter, then measurement can be performed, but an additional wireline trip is required which increases operation time and cost
Solution Approach 1:
The caliper tool is merged with the wireline assembly, allowing the caliper to be deployed alongside other wireline operations. The caliper tool includes a collar, measurement bands, sliding blocks, and electromagnetic sensors that integrate with the wireline system, enabling simultaneous deployment with drilling operations rather than requiring a separate trip.
Solution Approach 2:
The wireline assembly is designed to perform multiple functions: it serves both as the deployment mechanism for the caliper tool and as part of the drilling operation infrastructure. The caliper tool itself performs measurement while being transported by the wireline system, combining measurement and transport functions in a single system.
2Measurement precision
If measurement bands are extended to contact wellbore wall for accurate measurement, then diameter measurement is achieved, but measurement bands are exposed to damage from wellbore irregularities
Solution Approach 1:
The measurement bands are designed to be dynamic rather than static. They can extend radially outward from the collar to contact the wellbore wall when measurement is needed, and retract back to the collar when not in use. This dynamic extension and retraction allows the bands to perform their measurement function while minimizing exposure to damaging wellbore conditions.
Solution Approach 2:
The actuating mechanism includes a constraining member that holds the measurement bands in a protected position during deployment and transport. Before measurement begins, the constraining member fails in a controlled manner, allowing the measurement bands to extend to their measurement position. This preliminary constraint protects the bands during the vulnerable transport phase.
3Ease of operation
If actuating mechanism is activated to extend measurement bands, then measurement is enabled, but complex mechanical components are exposed to high pressure and potential failure
Solution Approach 1:
The actuating mechanism uses fluid pressure (pneumatics or hydraulics) to activate the measurement bands. A constraining member is designed to fail at a predetermined pressure threshold when fluid is pumped into the actuating mechanism. This pressure-activated failure mechanism provides a reliable and simple way to transition from the protected state to the measurement state without complex mechanical controls.
Solution Approach 2:
The constraining member is designed with specific material and geometric properties that cause it to fail at a predetermined pressure threshold. By changing the pressure parameter of the fluid system, the constraining member transitions from a constrained state to a failed state, which in turn activates the measurement bands. This parameter-based activation simplifies the control mechanism while maintaining reliability.
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 accurate wellbore diameter measurement during ongoing drilling operations, reducing time and cost by integrating diameter calculation into existing processes without additional wireline trips.
Implementation Method 1
Electromagnetic sensors in the caliper tool measure an electromagnetic field created by magnets in the sliding blocks
Implementation Method 2
springs can provide a force that extends the measurement bands
Implementation Method 3
The constraining member is configured to fail when fluid is pumped into the actuating mechanism and creates a differential pressure across the dynamic member above a certain threshold
Data Source
AI summary
A wellbore caliper tool is provided for measuring a wellbore diameter without an additional wireline trip. The caliper tool includes a collar, measurement bands coupled to the collar at one end and sliding blocks on the other. The measurement bands can extend radially from the collar, which causes the sliding blocks to move within the collar. Electromagnetic sensors in the collar measure an electromagnetic field created by magnets in the sliding blocks to determine the position of the sliding blocks. The position of the sliding blocks is used to calculate the distance that the measurement bands extend and to calculate the wellbore diameter. The caliper tool includes an actuating mechanism that holds the sliding blocks in place until a differential pressure is applied by pumping fluid into the caliper tool.