Wireless Sensors Embedded in Cement Sheath for Integrity Monitoring

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Solution Overview

Problem

Current tools for evaluating cement sheath integrity in oil and gas wells are limited, leading to casing and cementing failures that result in well blowouts, contamination, corrosion, and production cessation, as they rely on external acoustic techniques that are not always accurate and can only be assessed after cementing operations are completed.

Innovation Solution

Embedding passive, wireless sensors within the cement slurry that are pumped into the wellbore and embedded in the cement sheath, allowing for real-time monitoring of cement sheath parameters such as compressive strength, temperature, pressure, humidity, pH, and gases, with data transmitted wirelessly to a reader for timely remedial action.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If external acoustic techniques are used to evaluate cement sheath integrity, then the evaluation can be performed after cementing operations are completed, but the measurement precision and reliability are insufficient leading to casing and cementing failures

Engineering Contradiction:

Improvecement sheath integrity evaluation accuracyVSAvoidcasing and cementing integrity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

Wireless mobile sensing devices are embedded within the cement slurry during pumping, nesting the sensors inside the cement sheath structure. This allows direct internal measurement of cement integrity parameters, significantly improving measurement precision and reliability compared to external acoustic techniques.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

Wireless mobile devices act as intermediaries between the cement sheath and the evaluation system. These devices are pumped into the wellbore with the cement slurry and embedded in the cement sheath, providing real-time internal monitoring of cement integrity without requiring wellbore access later.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of time

If external acoustic tools are lowered into the wellbore after cementing, then the evaluation can be performed, but the timing is delayed preventing timely remedial actions

Engineering Contradiction:

Improvetime for cement integrity evaluationVSAvoidwell integrity

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

Wireless mobile sensing devices are pumped into the wellbore and embedded in the cement sheath during the cementing operation itself, before the cement sets. This preliminary placement enables continuous monitoring from the start, eliminating the need for later tool interventions and enabling timely detection of integrity issues.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The wireless sensors provide continuous monitoring of cement sheath integrity parameters from the moment of embedding during cementing through curing and into production. This continuous action ensures no critical integrity degradation goes undetected, enabling immediate remedial response.

Inventive Principle:

Principle #20Continuity of useful action

3Loss of information

If wireless mobile devices are dispersed in cement slurry and embedded in the cement sheath, then real-time monitoring of cement sheath parameters is achieved, but the device complexity increases

Engineering Contradiction:

Improvecement sheath parameter monitoring capabilityVSAvoidsensing system complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The wireless mobile devices are designed as multi-functional units that can sense multiple cement sheath parameters (integrity, temperature, pressure) and communicate wirelessly. This universal design consolidates multiple sensing functions into single devices, reducing overall system complexity while maintaining comprehensive monitoring capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The wireless mobile devices are self-contained units with integrated sensing, processing, and wireless communication capabilities. They autonomously monitor cement parameters and transmit data without requiring external power or control connections, simplifying the overall system architecture despite the advanced functionality of individual devices.

Inventive Principle:

Principle #25Self-service

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

Provides accurate and timely assessments of cement sheath integrity, reducing the risk of failures by enabling continuous monitoring and early detection of potential issues, thus ensuring well integrity and maintaining production potential.

Implementation Method 1

a piezoelectric crystal configured to receive an acoustic wave and convert the acoustic wave into electric energy

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS11649717B2Systems and methods for sensing downhole cement sheath parameters

Publication Date: 2023.05.16 SAUDI ARABIAN OIL CO

AI summary

Wireless mobile devices are injected into a wellbore with a cement slurry, during the cementing of casing, to monitor and evaluate cement sheath parameters. Passive, wireless sensors are utilized to not only measure the elastic constitutive properties of the cement sheath such as compressive strength, but also parameters of the cement sheath environment, such as temperature, pressure, humidity, pH and gases present, to identify potential issues about the structural integrity of the cement sheath, and provide timely warnings to perform remedial actions.