Wellbore Cement Plug Integrity Monitoring via Sealed Sensor Space

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Solution Overview

Problem

Existing methods for determining the long-term integrity of cement plugs in wellbores do not provide ongoing information about leaks or the integrity of hydrocarbon-bearing formations, relying primarily on pressure tests that are not sufficient for continuous monitoring.

Innovation Solution

A wellbore system with sensors placed in a sealed space between a plug and a seal above the cement section to measure parameters such as hydrocarbon presence, moisture, pressure, and temperature, which transmit data wirelessly or via communication links for continuous monitoring and analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pressure tests are performed to determine cement plug integrity, then integrity assessment is achieved, but long-term continuous monitoring capability is lost

Engineering Contradiction:

Improvecement plug integrity assessmentVSAvoidmonitoring duration

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

Sensors are installed in the sealed space above the cement plug before the well is abandoned, enabling continuous monitoring to begin immediately and providing long-term integrity data throughout the plug's service life

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor system provides continuous monitoring of pressure, temperature, and hydrocarbon presence in the sealed space, transforming the intermittent pressure test approach into an ongoing continuous assessment that lasts throughout the operational life of the cement plug

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If sensors are installed in a sealed space above the cement plug, then continuous monitoring capability is achieved, but device complexity increases

Engineering Contradiction:

Improveintegrity monitoring reliabilityVSAvoidsensor system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sealed space above the cement plug serves multiple functions: it provides a containment volume for sensors, acts as a monitoring chamber for detecting leaks, and enables long-term integrity assessment, thereby reducing the need for separate systems for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The sealed space acts as an intermediary medium between the cement plug and the sensors, allowing indirect detection of plug integrity through measurements of pressure, temperature, and hydrocarbon presence in the sealed environment, which simplifies the sensor installation and protection requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If continuous monitoring of hydrocarbon presence is implemented, then leak detection capability is improved, but measurement precision requirements increase

Engineering Contradiction:

Improveleak detection capabilityVSAvoidhydrocarbon detection precision

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

Continuous monitoring of hydrocarbon presence in the sealed space allows for the detection of even small leaks over time, where accumulated data trends provide reliable leak detection without requiring extremely high instantaneous measurement precision

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The sensor system provides continuous feedback on hydrocarbon presence, pressure, and temperature in the sealed space, allowing for trend analysis and early warning of potential leaks before they become critical, thereby reducing the burden on single-point measurement precision

Inventive Principle:

Principle #23Feedback

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 continuous and long-term monitoring of cement plug integrity, providing timely detection of leaks and ensuring the reliability of hydrocarbon-bearing formations by offering real-time data on key parameters.

Implementation Method 1

sensor in the space for providing measurements relating to a parameter of interest... presence and extent of a hydrocarbon in the space

Methodology Applied

Scientific EffectHydrocarbon detection:

Implementation Method 2

presence of moisture in the space

Methodology Applied

Scientific EffectMoisture detection:

Implementation Method 3

pressure

Methodology Applied

Scientific EffectPressure measurement:

Implementation Method 4

temperature

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 5

seal disposed uphole of the cement section to provide a space between the plug and the seal

Methodology Applied

Scientific EffectSealing:

Data Source

PatentUS9797218B2Wellbore systems with hydrocarbon leak detection apparatus and methods

Publication Date: 2017.10.24 BAKER HUGHES CO

AI summary

In one aspect, a wellbore system is disclosed that in one non-limiting embodiment includes a cement section in the wellbore formed to prevent flow of fluids including hydrocarbons through the cement section, a plug disposed uphole of the cement section to provide a space between the cement section and the plug and a sensor in the space for providing measurements relating to a parameter of interest. In one aspect, the parameter of interest may include one or more of presence and extent of a hydrocarbon, presence of moisture; pressure; and temperature. The system may further include a transmitter that transmits measurements from the sensor via a communication line or wirelessly to a receiver for processing the sensor measurements.