Flexible piezoelectric for downhole sensing, actuation and health monitoring

• US 20040200613A1
• Filed: 04/08/2003
• Published: 10/14/2004
• Est. Priority Date: 04/08/2003
• Status: Active Grant

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Schultz, Roger L., Fripp, Michael L., Rodgers, John P.
• Granted Patent: US 7,234,519 B2
• Time in Patent Office: Days
• US Class Current: 166/250.01
• CPC Class Codes: E21B 47/007 Measuring stresses in a pipe string or casing for locating blocked portions of pipes E21B47/09
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves

Abstract

Thin flexible piezoelectric transducers are bonded to or imbedded into oilfield tubular members or structural members. The transducers may be used to telemeter data as acoustic waves through the members. By proper spacing of transducers and phasing of driving signals, the transmitted signals can be directionally enhanced or encoded to improve transmission efficiency. The transducers may be used for health monitoring of the tubular or structural members to detect cracks, delaminations, or other defects. The flexible transducers are very thin so that overall dimensions of tubular or structural members are essentially unchanged by incorporation of the transducers.

Claims

1. Apparatus comprising:

a section of a wellbore tubular member, and

a flexible piezoelectric device bonded to the wellbore tubular member.

2. Apparatus according to claim 1, further comprising a plurality of flexible piezoelectric devices bonded to the wellbore tubular member.

3. Apparatus according to claim 2, wherein the flexible piezoelectric devices are bonded to the wellbore tubular member at locations axially displaced along the drill pipe.

4. Apparatus according to claim 3, wherein the locations are uniformly displaced along the wellbore tubular member.

5. Apparatus according to claim 3, wherein the locations are nonuniformly displaced along the wellbore tubular member with a spacing which defines a telemetry code.

6. Apparatus according to claim 2, wherein a plurality of the flexible piezoelectric devices are bonded to the wellbore tubular member at the same location with at least one device stacked on top of another device.

7. Apparatus according to claim 1, wherein each flexible piezoelectric device has a length, a width and a thickness, has a mechanical response aligned with the length, and is bonded to the wellbore tubular member with its length dimension in alignment with the wellbore tubular member central axis.

8. Apparatus according to claim 7, wherein the thickness dimension is between 0.001 and 0.025 inch.

9. Apparatus according to claim 8, wherein the thickness dimension is about 0.010 inch.

10. Apparatus according to claim 1, wherein the flexible piezoelectric device is bonded to an outer surface of the wellbore tubular member.

11. Apparatus according to claim 1, wherein the flexible piezoelectric device is bonded to an inner surface of the wellbore tubular member.

12. Apparatus according to claim 1, wherein the flexible piezoelectric device is imbedded within a wall of the wellbore tubular member.

13. Apparatus according to claim 1, wherein the flexible piezoelectric device has a length, a width and a thickness, has a mechanical response aligned with the length, and is bonded to the wellbore tubular member with its length dimension tilted by thirty to sixty degrees relative to the wellbore tubular member central axis, whereby the device may produce torsional waves in said wellbore tubular member.

14. Apparatus according to claim 1, wherein the flexible piezoelectric device has a length, a width and a thickness, has a mechanical response aligned with the length, and is bonded to the wellbore tubular member with its length dimension tilted by about ninety degrees relative to the wellbore tubular member central axis, whereby said device may produce hoop waves in said wellbore tubular member.

15. Apparatus according to claim 1, wherein the flexible piezoelectric device comprises a generally flat slab of piezoelectric material having a length, a width and a thickness, the slab having grooves along at least one side, said grooves aligned substantially with the length of the slab and reducing the slab thickness sufficiently to increase flexibility of the slab.

16. Apparatus according to claim 15, wherein the grooves have widths and depths which vary along the length of the slab, whereby the device generates a shaped waveform.

17. Apparatus according to claim 15, wherein the slab width varies along its length, whereby the device generates a shaped waveform.

18. Apparatus according to claim 15, further comprising:

first and second flexible insulating films, and

interdigitated electrode patterns carried on the first and second films, the first and second films bonded to opposite sides of the slab, with the electrode patterns in contact with the slab and in alignment with each other.

19. A borehole telemetry system, comprising:

a tubular member adapted for use in a borehole, and

at least one flexible piezoelectric transducer bonded to the tubular member.

20. A borehole telemetry system according to claim 19, further comprising a telemetry driver having an electrical output coupled to the at least one flexible piezoelectric transducer.

21. A borehole telemetry system according to claim 19, further comprising a plurality of flexible piezoelectric transducers bonded to the tubular member.

22. A borehole telemetry system according to claim 21, further comprising a telemetry driver having separate electrical outputs coupled to each of the plurality of flexible piezoelectric transducers.

23. A borehole telemetry system according to claim 22, wherein:

the plurality of flexible piezoelectric transducers are axially displaced along the tubular member, and

the telemetry driver electrical outputs to each of the plurality of flexible piezoelectric transducers are phase shifted relative to each other.

24. A borehole telemetry system according to claim 23, wherein the phase shifts are selected to cause said transducers to generate directionally enhanced acoustic signals in the tubular member.

25. A borehole telemetry system according to claim 21, wherein the plurality of flexible piezoelectric devices are nonuniformly displaced along the length of the tubular member with a spacing which defines a telemetry code.

26. A borehole telemetry system according to claim 19, further comprising a telemetry receiver having an electrical input coupled to the at least one flexible piezoelectric transducer.

27. A borehole telemetry system according to claim 21, further comprising a telemetry receiver having separate electrical outputs coupled to each of the plurality of flexible piezoelectric transducers.

28. A borehole telemetry system according to claim 27, wherein:

the plurality of flexible piezoelectric transducers are axially displaced along the tubular member, and

the telemetry receiver electrical inputs from each of the plurality of flexible piezoelectric transducers are phase shifted relative to each other.

29. A borehole telemetry system according to claim 28, wherein the phase shifts are selected to cause said transducers to receive acoustic signals traveling in one direction in the tubular member.

30. A system for monitoring health of a structural member, comprising:

a structural member adapted for use in an oil production system, and

a first flexible piezoelectric transducer bonded to the structural member.

31. A system according to claim 30, further comprising a capacitance detector coupled to the first transducer and measuring capacitance of the first transducer.

32. A system according to claim 30, further comprising a second piezoelectric transducer bonded to the structural member at a location displaced from the first piezoelectric transducer.

33. A system according to claim 32, further comprising:

a signal driver coupled to the first transducer generating an acoustic signal in said structure, and

a signal receiver coupled to the second transducer detecting the acoustic signal from said first transducer.

34. A system according to claim 32, further comprising a memory coupled to said signal receiver storing characteristics of the signal received by said second transducer.

35. A system according to claim 30, wherein:

the structural member comprises a composite material, and

the first transducer is imbedded in said composite material.

36. A system according to claim 35, further comprising an antenna coupled to the first transducer and imbedded in the composite material.

37. A system according to claim 36, further comprising a transponder having an electromagnetic port for coupling signals to and from said antenna.

38. A system according to claim 30, further comprising a receiver coupled to said transducer receiving acoustic signals produced by defects in the structure.

39. A system according to claim 38, further comprising a signal analyzer coupled to said receiver identifying the acoustic signals as indications of defects in the structure.

40. A system for detecting the flow of material through a tubular element, comprising:

a tubular element adapted for flowing materials in a hydrocarbon production system, and

a flexible piezoelectric transducer bonded to the tubular element.

41. A system according to claim 40, further comprising a signal receiver coupled to the electrical connection of the flexible piezoelectric transducer receiving signals produced by materials flowing in the tubular element.

42. A system according to claim 41, further comprising a signal analyzer coupled to said receiver identifying the signals as indications of material flow in the tubular element.

43. A system according to claim 42, wherein said material flowing in said tubular element comprises liquid material and particulate material carried in said fluid.

44. A system according to claim 43, wherein the signal analyzer identifies signals produced by the particulate material.

45. A method for converting between electrical energy and acoustic energy in a borehole tubular member, comprising bonding a flexible piezoelectric device to a borehole tubular member.

46. A method according to claim 45, wherein the flexible piezoelectric device is bonded to a curved surface of the borehole tubular member.

47. A method according to claim 45, further comprising coupling an electrical transmitter to an electrical connection of the flexible piezoelectric device.

48. A method according to claim 45, further comprising coupling an electrical receiver to an electrical connection of the flexible piezoelectric device.

49. A method according to claim 48, further comprising using energy received from the flexible piezoelectric device as an electrical power source.

50. A method according to claim 48, further comprising charging a battery with energy received from the flexible piezoelectric device.

51. A method for telemetering data in a borehole, comprising:

bonding a mechanical connection of a first flexible piezoelectric device to a tubular member adapted for use in a borehole, and

coupling electrical signals to an electrical connection of the first flexible piezoelectric device.

52. A method according to claim 51, further comprising:

bonding a plurality of the first flexible piezoelectric devices to the tubular member at locations axially displaced along the tubular member, and

coupling electrical signals to electrical connections of each of the plurality of the first flexible piezoelectric devices.

53. A method according to claim 52, further comprising phase shifting the electrical signals coupled to each of the plurality of the first flexible piezoelectric devices, whereby a directionally enhanced acoustic signal is induced in the tubular member.

54. A method according to claim 51, further comprising:

bonding a mechanical connection of a second flexible piezoelectric device to the tubular member, and

receiving electrical signals from an electrical connection of the second flexible piezoelectric device.

55. A method according to claim 54, further comprising:

bonding a plurality of the second flexible piezoelectric devices to the tubular member at locations axially displaced along the tubular member, and

receiving electrical signals from electrical connections of each of the plurality of the first flexible piezoelectric devices.

56. A method according to claim 55, further comprising phase shifting and combining the electrical signals received each of the plurality of the second flexible piezoelectric devices, whereby a directionally enhanced acoustic signal is received from the tubular member.

57. A method for monitoring mechanical health of a structural member in an oil production system, comprising bonding a mechanical connection of a flexible piezoelectric transducer to a structural member adapted for use in an oil production system.

58. A method according to claim 57, further comprising receiving electrical signals generated at the electrical connection of the flexible piezoelectric transducer by acoustic energy in the structural member.

59. A method according to claim 58, further comprising analyzing the received electrical signals for indications of defects in the structural member.

60. A method according to claim 58, further comprising applying an external force to the structural member.

61. A method for detecting the flow of material through a tubular element in a hydrocarbon production system, comprising bonding a mechanical connection of a flexible piezoelectric transducer to a tubular element adapted for flowing materials in an oil production system.

62. A method according to claim 61, further comprising receiving electrical signals generated at the electrical connection of the flexible piezoelectric transducer by acoustic energy in the tubular member.

63. A method according to claim 62, further comprising analyzing the received electrical signals to identify materials flowing in the tubular member.

64. A method according to claim 61, further comprising driving said transducer with an electrical signal to induce vibrations in the tubular element.

65. A method according to claim 64, further comprising analyzing the response of the tubular element to the vibrations to measure at least one parameter of fluid within the tubular element.

66. A method according to claim 65, wherein said parameter is one of viscosity, density and ratio of water to oil.

67. A method for transmitting and receiving acoustic waves in a tubular element in a hydrocarbon production system, comprising:

bonding at least first and second flexibly piezoelectric transducers to a tubular element adapted for use in a hydrocarbon production system, said transducers having a directional mechanical connection, the mechanical connection of the first transducer positioned at a first angle relative to the axis of the tubular element, and

the mechanical connection of the second transducer positioned at a second angle relative to the axis of the tubular element, the second angle being different from the first angle.

68. A method according to claim 67, wherein the first transducer is substantially in alignment with the axis of the tubular element and the second transducer is substantially out of alignment with the axis of the tubular element.

69. A method according to claim 68 further comprising:

receiving acoustic waves with the first and second transducers, and

analyzing the received acoustic waves to estimate the distance to the source of the acoustic waves.

70. A method according to claim 68, further comprising:

using the first transducer to telemeter data through the tubular element, and

using the second transducer to telemeter an acoustic wave which at least partially cancels an acoustic wave generated by a noise source.

71. Apparatus comprising:

a section of a wellbore tubular member, and

a thin piezoelectric device bonded to the wellbore tubular member.

72. Apparatus according to claim 71, wherein the thin piezoelectric device has a length, a width and a thickness and has one of its major planar surfaces bonded to a surface of the wellbore tubular member.

73. Apparatus according to claim 72, wherein the thin piezoelectric device has a mechanical response aligned with the length, and is bonded to the wellbore tubular member with its length dimension in alignment with the wellbore tubular member central axis.

74. Apparatus according to claim 72, further comprising:

first and second flexible insulating films, and

interdigitated electrode patterns carried on the first and second films, the first and second films bonded to opposite major planar surfaces of the device, with the electrode patterns in contact with the device and in alignment with each other.

75. Apparatus according to claim 72, wherein the thickness dimension is between 0.001 and 0.025 inch.

76. Apparatus according to claim 75, wherein the thickness dimension is about 0.010 inch.

77. A system for monitoring health of a structural member, comprising:

a structural member adapted for use in an oil production system, and

a thin piezoelectric transducer bonded to the structural member.

78. Apparatus according to claim 77, wherein the thin piezoelectric device has a length, a width and a thickness and has one of its major planar surfaces bonded to a surface of the structural member.

79. Apparatus according to claim 78, further comprising:

first and second flexible insulating films, and

interdigitated electrode patterns carried on the first and second films, the first and second films bonded to opposite major planar surfaces of the device, with the electrode patterns in contact with the device and in alignment with each other.

80. Apparatus according to claim 79, wherein the thickness dimension is between 0.001 and 0.025 inch.

81. Apparatus according to claim 80, wherein the thickness dimension is about 0.010 inch.