X-ray Wellbore Imaging Tool for Casing Integrity
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Solution Overview
Problem
Current methods for monitoring and determining casing and sand-screen integrity in wellbore environments are inadequate, as they lack the ability to produce complete backscatter images of casings using a combination of collimators and rotatable two-dimensional per-pixel collimated imaging detectors, especially in environments with non-optically clear fluids or mud-cake/fluid variations.
Innovation Solution
An x-ray-based cased wellbore environment imaging tool employing an x-ray source, radiation shield, direction-controllable two-dimensional per-pixel collimated imaging detector arrays, and sonde-dependent electronics, which produces shaped x-rays, measures backscatter x-rays, and converts image data into consolidated images, allowing for cylindrical imaging and inspection without direct physical contact with the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cameras are employed to determine casing quality, then the wellbore must contain optically clear fluids, but this requirement limits the method's applicability in environments with non-clear fluids or mud-cake variations
Solution Approach 1:
The patent replaces optical detection systems (cameras) with x-ray detection systems. The x-ray source emits radiation through the casing and surrounding materials, and x-ray detectors capture the transmitted or backscattered radiation to create images of casing integrity, corrosion, and foreign objects. This substitution eliminates the requirement for optically clear fluids while maintaining high measurement precision for casing quality assessment.
Solution Approach 2:
The patent changes the physical parameter used for imaging from optical properties (light transmission) to x-ray attenuation properties. By using x-ray radiation with appropriate energy levels, the system can penetrate through casings, fluids, and surrounding materials regardless of optical clarity, thereby expanding adaptability to various wellbore environments while preserving detailed imaging capability.
2Measurement precision
If ultrasonic tools are used to image casing and surrounding elements, then prior knowledge of the precise makeup and status of the well is required, but this increases the complexity of data interpretation
Solution Approach 1:
The patent replaces ultrasonic imaging with x-ray imaging. X-ray attenuation coefficients are intrinsic material properties that can be directly related to material composition and density without requiring complex acoustic models. The x-ray system captures direct transmission or backscatter images that provide intuitive visual information about casing integrity, corrosion, and foreign objects, reducing the need for prior knowledge and complex data interpretation.
Solution Approach 2:
The patent creates direct visual copies (images) of the casing and surrounding structures using x-ray radiation. The x-ray detectors capture the radiation pattern after interaction with the casing, producing images that directly represent the physical state of the casing wall thickness, corrosion, and foreign objects without requiring intermediate modeling or comparison against theoretical acoustic models.
3Productivity
If conventional x-ray methods are used without per-pixel collimation, then the ability to resolve fine details and create high-quality images is reduced
Solution Approach 1:
The patent divides the detector into multiple pixels, with each pixel having its own collimator element. This segmentation allows each pixel to independently detect x-rays from specific angular directions, enabling precise spatial resolution of the imaged features. The collimated x-ray backscatter imaging system with per-pixel collimation creates high-quality images by resolving fine details in the casing wall thickness, corrosion, and foreign objects while maintaining efficient imaging speed through parallel detection across all pixels.
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, non-contact imaging of wellbore materials, including casings, sand-screens, and perforations, providing high-quality, two-dimensional images that can detect corrosion, holes, cracks, and scale-buildup, with the option for machine learning analysis to enhance image quality and feature identification.
Implementation Method 1
measuring the intensity of backscatter x-rays returning from materials surrounding the wellbore
Data Source
AI summary
An x-ray-based cased wellbore environment imaging tool is provided, the tool including at least an x-ray source; a radiation shield to define the output form of the produced x-rays; a direction controllable two-dimensional per-pixel collimated imaging detector array; sonde-dependent electronics; and a plurality of tool logic electronics and PSUs. A method of using an x-ray-based cased wellbore environment imaging tool to monitor and determine the integrity of materials within wellbore environments is also provided, the method including at least: producing x-rays in a shaped output; measuring the intensity of backscatter x-rays returning from materials surrounding the wellbore; controlling two-dimensional per-pixel collimated imaging detector arrays; and converting image data from said detectors into consolidated images of the wellbore materials.