MEMS-based transducers on a downhole tool

• US 10,365,389 B2
• Filed: 11/17/2015
• Issued: 07/30/2019
• Est. Priority Date: 11/17/2015
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Gilstrap, Tatiana, Lu, Yinghui, Granville, John P., Zheng, Yibing, Welsh, David Alan
• Primary Examiner(s): Breier, Krystine E
• Application Number:
  US15/511,868
• Publication Number:
  US 20170293044A1
• Time in Patent Office: 1,351 Days
• CPC Class Codes: B29D 2030/0072 Attaching fasteners to tyres, e.g. patches, in order to connect devices to tyres
• CPC Class Codes: B29D 2030/0077 Directly attaching monitoring devices to tyres before or after vulcanization, e.g. microchips
• CPC Class Codes: B29D 2030/0083 Attaching monitoring devices to tyres before or after vulcanization by inserting them inside tyre cavities
• CPC Class Codes: B60C 23/0493 for attachment on the tyre
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: E21B 47/0025 generating an image of the borehole wall using down-hole measurements, e.g. acoustic or electric
• CPC Class Codes: E21B 47/005 Monitoring or checking of cementation quality or level
• CPC Class Codes: E21B 47/107 using acoustic means
• CPC Class Codes: F16B 2/22 of resilient material, e.g. rubbery material F16B2/205 takes precedence
• CPC Class Codes: G01V 1/46 Data acquisition
• CPC Class Codes: G01V 1/50 Analysing data
• CPC Class Codes: G01V 1/52 Structural details
• CPC Class Codes: G01V 2210/1299 Subsurface, e.g. in borehole or below weathering layer or mud line
• CPC Class Codes: G01V 2210/1429 Subsurface, e.g. in borehole or below weathering layer or mud line
• CPC Class Codes: H05K 5/0204 Mounting supporting structures on the outside of casings

Abstract

In accordance with embodiments of the present disclosure, systems and methods for taking acoustic/ultrasonic wave measurements of a wellbore using a downhole tool equipped with microelectromechanical (MEM) transducers are provided. The MEM transducers may include a plurality of MEM transmitters (e.g., MEM speakers) and a plurality of separate MEM receivers (e.g., MEM microphones). These MEM transducers may be disposed in arrays proximate an outer surface of the downhole tool to collect acoustic/ultrasonic wave measurements of the full circumference of a wellbore. Due to their small size, large numbers of MEM transducers may be distributed radially around the downhole tool. Such an arrangement of sensors may enable the downhole tool to perform measurements of the entire wellbore without the downhole tool needing to be rotated, leading to an increased signal-to-noise ratio of the measurements.

Claims

1. A system, comprising:

a downhole tool;

a plurality of microelectromechanical (MEM) transmitters disposed proximate an outer surface of the downhole tool for outputting one or more acoustic or ultrasonic signals toward a wellbore; and

a plurality of MEM receivers disposed proximate the outer surface of the downhole tool for receiving a portion of the one or more acoustic or ultrasonic signals reflected back from the wellbore;

wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are disposed in arrays, wherein the arrays are either;

circular arrays, each circular array being positioned at a different circumferential location around the downhole tool, wherein each circular array comprises a plurality of MEM transmitters and/or MEM receivers that are;

spaced from each other circumferentially around a center point of the circular array; and

each located equidistant from the center point of the circular array;

or

rectangular arrays, each rectangular array being positioned at a different circumferential location around the downhole tool, wherein a space in a circumferential direction about the downhole tool between adjacent rectangular arrays is greater than a space in a circumferential direction between adjacent MEM transmitters and/or MEM receivers located in any one of the rectangular arrays.

2. The system of claim 1, wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are coupled directly to the outer surface of the downhole tool.

3. The system of claim 1, wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are mounted on mechanical arms that are selectively extendable away from the outer surface of the downhole tool.

4. The system of claim 1, wherein the plurality of MEM transmitters are disposed on a first circumferential band around the downhole tool, the plurality of MEM receivers are disposed on a second circumferential band around the downhole tool, and the first and second circumferential bands are offset along an axis of the downhole tool.

5. The system of claim 1, further comprising a protective coating disposed over one or more of the plurality of MEM transmitters and the plurality of MEM receivers.

6. The system of claim 1, wherein the plurality of MEM transmitters and the plurality of MEM receivers are at least partially recessed into the downhole tool.

20. The system of claim 1, wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are disposed in a three-dimensional arrangement with respect to each other.

7. A method, comprising:

outputting one or more acoustic or ultrasonic signals toward a wellbore via a plurality of microelectromechanical (MEM) transmitters disposed proximate an outer surface of a downhole tool;

detecting at least a portion of the one or more acoustic or ultrasonic signals reflected back from the wellbore via a plurality of MEM receivers disposed proximate the outer surface of the downhole tool;

processing the detected portion of the one or more acoustic or ultrasonic signals to determine a property of the wellbore via a processing component communicatively coupled to the plurality of MEM receivers; and

generating a 3-dimensional map of the wellbore, a 3-dimensional map of a casing disposed within the wellbore, or a cement bond log of cement in an annulus between the casing and a formation, based on the property determined via the processing component;

wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are disposed in arrays, wherein the arrays are either;

circular arrays, each circular array being positioned at a different circumferential location around the downhole tool, wherein each circular array comprises a plurality of MEM transmitters and/or MEM receivers that are;

spaced from each other circumferentially around a center point of the circular array; and

each located equidistant from the center point of the circular array;

or

rectangular arrays, each rectangular array being positioned at a different circumferential location around the downhole tool, wherein a space in a circumferential direction about the downhole tool between adjacent rectangular arrays is greater than a space in a circumferential direction between adjacent MEM transmitters and/or MEM receivers located in any one of the rectangular arrays.

8. The method of claim 7, further comprising outputting the one or more acoustic or ultrasonic signals at an oblique angle toward the wellbore.

9. The method of claim 7, further comprising focusing a plurality of acoustic or ultrasonic signals output from the plurality of MEM transmitters to target a wellbore layer.

10. The method of claim 7, further comprising outputting the one or more acoustic or ultrasonic signals and detecting at least a portion of the one or more acoustic or ultrasonic signals multiple times while raising or lowering the downhole tool through the wellbore.

11. The method of claim 7, further comprising determining whether fluid is present in an annulus between a casing of the wellbore and a formation, based on the property of the wellbore determined via the processing component.

12. The method of claim 7, further comprising maintaining the downhole tool at approximately the same orientation relative to a longitudinal axis of the downhole tool while determining the property of the wellbore around a full circumference of the wellbore.

13. The method of claim 7, further comprising scanning a wall of the wellbore by controlling a phase of the plurality of MEM transmitters outputting the one or more acoustic or ultrasonic signals.

14. The method of claim 7, wherein processing the detected portion of the one or more acoustic or ultrasonic signals comprises performing one or more array processing techniques on multiple acoustic or ultrasonic signals, the one or more array processing techniques being selected from the group consisting of:

semblance-based imaging, beamforming, slant stacks, and vespagrams.

15. The method of claim 7, comprising generating the 3-dimensional map of the wellbore or the 3-dimensional map of a casing disposed within the wellbore.

16. The method of claim 7, wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are disposed in circular arrays, each circular array being positioned at a different circumferential location around the downhole tool, wherein each circular array comprises a plurality of MEM transmitters and/or MEM receivers that are:

spaced from each other circumferentially around a center point of the circular array; and

each located equidistant from the center point of the circular array.

17. The method of claim 7, wherein the plurality of MEM transmitters, the plurality of MEM receivers, or both are disposed in rectangular arrays, each rectangular array being positioned at a different circumferential location around the downhole tool, wherein a space in a circumferential direction about the downhole tool between adjacent rectangular arrays is greater than a space in a circumferential direction between adjacent MEM transmitters and/or MEM receivers located in any one of the rectangular arrays.

18. The method of claim 7, further comprising controlling a timing of the operation of the plurality of MEM transmitters and MEM receivers to collect multiple sets of measurements, and determining multiple different properties of the wellbore based on the multiple sets of measurements.

19. A system, comprising:

a downhole tool;

a plurality of microelectromechanical (MEM) transmitters disposed proximate an outer surface of the downhole tool for outputting one or more acoustic or ultrasonic signals toward a wellbore;

a plurality of MEM receivers disposed proximate the outer surface of the downhole tool for receiving a portion of the one or more acoustic or ultrasonic signals reflected back from the wellbore, wherein the plurality of MEM transmitters and the plurality of MEM receivers are randomly interspersed amongst each other on the downhole tool; and

a controller communicatively coupled to the plurality of MEM transmitters and MEM receivers, wherein the controller controls a timing of the operation of the plurality of MEM transmitters and MEM receivers to collect multiple different downhole measurements using the same plurality of MEM transmitters and MEM receivers.