Downhole system with integrated backup sensors

• US 10,422,921 B2
• Filed: 08/27/2018
• Issued: 09/24/2019
• Est. Priority Date: 06/19/2014
• Status: Active Grant

• Current Assignee: Evolution Engineering Inc .
• Original Assignee: Evolution Engineering Inc .
• Inventors: Logan, Aaron W., Derkacz, Patrick R., Logan, Justin C., Buternowsky, Barry Daniel, Kazemi Miraki, Mojtaba
• Primary Examiner(s): Bryant, Michael C
• Application Number:
  US16/113,735
• Publication Number:
  US 20190004209A1
• Time in Patent Office: 393 Days
• CPC Class Codes: E21B 47/01 Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like
• CPC Class Codes: G01T 7/005 calibration techniques stabilization of spectrometer G01T1/40
• CPC Class Codes: G01V 13/00 Manufacturing, calibrating, cleaning, or repairing instruments or devices covered by groups G01V1/00 – G01V11/00
• CPC Class Codes: G01V 5/04 specially adapted for well-logging
• CPC Class Codes: G01V 5/12 using gamma or X-ray sources gamma sources using isotopes G21G4/00; X-ray tubes H01J35/00

Abstract

A downhole system comprises a main sensor, such as a gamma sensor, and a backup sensor. The backup sensor may be of a different type from the main sensor. In some embodiments the backup sensor is a high reliability sensor that may have a different sensitivity from the main sensor. The system operates both the main and backup sensors and generates calibration data for the backup sensor. If the main sensor fails the calibration data may be applied to process data from the backup sensor to yield an estimate of the data that the main sensor would have yielded if it had remained operational. The calibration data may compensate for temperature variations and/or temporal drift, for example.

Claims

1. Apparatus for monitoring downhole conditions, the apparatus comprising:

a first sensor operable to sense an environmental property;

a second sensor operable to sense the environmental property; and

a controller configured to;

obtain a first calibration sensor reading acquired by the first sensor at a first time;

obtain a second calibration sensor reading acquired by the second sensor at substantially the first time;

determine, based at least on the first and second calibration sensor readings, calibration information for the second sensor;

obtain a backup sensor reading acquired by the second sensor at a second time subsequent to the first time;

determine, based on the calibration information and the backup sensor reading a replacement sensor reading, the replacement sensor reading being an estimate of a sensor reading by the first sensor at the second time.

2. The apparatus according to claim 1 wherein the controller is configured to calibrate the second sensor such that readings of the second sensor match corresponding readings of the first sensor and the replacement sensor reading is the backup sensor reading.

3. The apparatus according to claim 1 wherein:

the controller is configured to obtain a first plurality of readings by the first sensor, the first plurality of readings including the first calibration sensor reading, and a corresponding second plurality of readings by the second sensor, the second plurality of readings including the second calibration reading, wherein the first and second pluralities of readings are obtained at times prior to the second time; and

the controller is configured to determine the calibration information for the second sensor based on the first and second pluralities of readings.

4. A system according to claim 1 comprising a downhole tool comprising the first and second sensors, surface equipment and a telemetry system providing data communication between the downhole tool and the surface equipment.

5. The apparatus according to claim 4 wherein the controller is configured to provide the replacement sensor reading to the surface equipment by way of the telemetry system in response to detecting a failure of the first sensor.

6. The apparatus according to claim 4 wherein determining the replacement sensor reading is performed at the surface equipment.

7. The apparatus according to claim 4 wherein determining the replacement sensor reading is performed at the downhole tool.

8. The apparatus according to claim 1 wherein each of the first and second sensors is housed in a rotatable element in the downhole system and the downhole system comprises shielding on one or more sides of the first and second sensors, wherein the first sensor senses the environmental property in substantially a first direction and the second sensor senses the environmental property in substantially a second direction different from the first direction.

9. The apparatus according to claim 8 wherein:

the first sensor travels along a circumferential path while the rotatable element rotates;

a plurality of circumferential segments are defined on the circumferential path, each of the circumferential segments associated with a bin; and

for each of the circumferential segments, sensor readings acquired by the first sensor while travelling along the circumferential segment are associated with the bin associated with the circumferential segment.

10. The apparatus according to claim 1 wherein the first sensor comprises a multi-directional sensor operable to sense the environmental property in a plurality of directions and the second sensor comprises one or more unidirectional sensors.

11. The apparatus according to claim 10 wherein each of the one or more unidirectional sensors is configured to sense in one of the plurality of directions.

12. The apparatus according to claim 10 comprising a processor configured to determine the replacement sensor reading based on, for at least a first one of the plurality of directions, a sensor reading acquired by the first sensor and based on, for at least a second one of the plurality of directions, the backup sensor reading.

13. The apparatus according to claim 12 wherein the processor is in communication with a telemetry system and the processor is configured to transmit one or both of the backup sensor reading and the replacement sensor reading via the telemetry system.

14. The apparatus according to claim 1 wherein the first and second sensors share a physical interface with the controller.

15. The apparatus according to claim 1 comprising a first physical interface interfacing the first sensor to the controller and a second physical interface interfacing the second sensor to the controller.

16. The apparatus according to claim 1 wherein the first sensor comprises a gamma radiation sensor comprising a photomultiplier tube.

17. The apparatus according to claim 16 wherein the second sensor comprises a solid-state gamma radiation sensor.

18. The apparatus according to claim 17 wherein the second sensor is a diode-based gamma radiation sensor.

19. The apparatus according to claim 1 wherein the controller is configured to continually calibrate the second sensor against the first sensor while the first sensor is operative.

20. The apparatus according to claim 1 wherein the controller is configured to obtain a reading taken by a third sensor taken substantially at the first time, wherein the third sensor is configured to sense a second environmental property distinct from the environmental property and the controller is configured to base the calibration information for the second sensor in part on the reading taken by the third sensor.

21. The apparatus according to claim 1 wherein the controller is configured to transmit the calibration information to surface equipment together with readings from the second sensor.

22. The apparatus according to claim 21 wherein the transmitted calibration information comprises a scale factor.

23. The apparatus according to claim 22 wherein the transmitted calibration information comprises an offset.

24. The apparatus according to claim 21 wherein the transmitted calibration information includes a parameter representing a rate of drift of a parameter of the calibration information.

25. The apparatus according to claim 21 wherein the controller is configured to transmit the calibration information to the surface equipment together with a measure of quality of a current calibration, the measure of quality comprising a residual based on differences between one or more readings of the first sensor and one or more corresponding estimated replacement sensor readings.

26. The apparatus according to claim 1 comprising a downhole tool wherein the first and second sensors are contained in a housing of the downhole tool.