sensors
Review Downhole Applications of Magnetic Sensors
Chinthaka P. Gooneratne *, Bodong Li and Timothy E. Moellendick
Drilling Technology Team, Exploration and Petroleum Engineering Center—Advanced Research Center (EXPEC-ARC), Dhahran 31311, Saudi Arabia; [email protected] (B.L.); [email protected] (T.E.M.) * Correspondence: [email protected]; Tel.: +966-(0)53-578-4190
Received: 12 August 2017; Accepted: 12 October 2017; Published: 19 October 2017
Abstract: In this paper we present a review of the application of two types of magnetic sensors—fluxgate magnetometers and nuclear magnetic resonance (NMR) sensors—in the oil/gas industry. These magnetic sensors play a critical role in drilling wells safely, accurately and efficiently into a target reservoir zone by providing directional data of the well and acquiring information about the surrounding geological formations. Research into magnetic sensors for oil/gas drilling has not been explored by researchers to the same extent as other applications, such as biomedical, magnetic storage and automotive/aerospace applications. Therefore, this paper aims to serve as an opportunity for researchers to truly understand how magnetic sensors can be used in a downhole environment and to provide fertile ground for research and development in this area. A look ahead, discussing other magnetic sensor technologies that can potentially be used in the oil/gas industry is presented, and what is still needed in order deploy them in the field is also addressed.
Keywords: fluxgate magnetometer; nuclear magnetic resonance; magnetic sensors; drilling technology; oil and gas; petroleum; downhole; harsh environment; high pressure high temperature (HPHT)
1. Introduction Magnetic sensors have been used in an extraordinary number of applications over the years, in the fields as diverse as automation, automotive, aerospace, biomedicine, computers, security, robotics, smart grids and textile technologies [1–19], and their utilization continues to increase at a rapid rate due to the advancements made in the area of nano-/microfabrication. In this paper, the application of magnetic sensors in the oil/gas industry, a relatively unexplored area of research compared with some of the aforementioned applications, is presented. Declining resources have forced oil/gas companies to drill deeper in different directions, and in more extreme and unknown environments. Therefore, it is important to monitor and analyze downhole environments in real-time when drilling a well in order to make timely decisions to optimize efficiency as well as prevent costly errors. One of the main ways of maximizing access to an oil/gas reservoir is to drill directional wells [20,21]. Directional drilling is the intentional deviation of a well from a vertical path at a predetermined trajectory, which allows access to reservoirs that cannot be reached efficiently with a vertical well drilled from the surface and maximizing reachability inside a reservoir. Therefore, directional drilling is used to optimize the production of hydrocarbons. Moreover, by drilling multiple directional wells from a drilling platform rather than drilling several vertical wells the drilling cost, impact on the environment and health and safety issues can be reduced. When planning directional wells, there are many considerations that have to be taken into account, such as target location, shape and size, well trajectory, geological formations, adjacent wells and rig surface facilities. The deviation of the well has to be accurately controlled in order to keep the trajectory of the well within the prescribed angle in order to reach the intended target. Failure to accurately drill a directional well can result in a ‘dry hole’, and significant financial losses for the company, as well as impacting their business strategy.
Sensors 2017, 17, 2384; doi:10.3390/s17102384 www.mdpi.com/journal/sensors Sensors 2017, 17, 2384 2 of 32
The oil/gas industry exploits the affordable, rugged, compact and reliable features of magnetic sensors, using them in harsh downhole environments. Fluxgate magnetometers (FGMs) and nuclear magnetic resonance (NMR) sensors play a significant role in optimizing well placement and completion resulting in maximum access to oil/gas reservoirs and higher production rates. In this paper we describe how FGMs and NMR sensors are utilized to obtain measurements inside wells during the drilling process so that wells can safely and efficiently reach oil/gas reservoirs located thousands of feet below the ground whilst also obtaining maximum access to these reservoirs. FGMs give the driller at the surface a means of navigating a well, whereas NMR sensors provide information about the geological characteristics of the formations being drilled through, in real-time.
2. Downhole Magnetometers
2.1. Principles of Fluxgate Magnetometers Since their inception in the 1930s, FGMs have been used to measure magnetic fields in a wide range of applications [22–24] and have recently progressed to solid-state sensors with the advancements made in micro/nanofabrication technology. Thorough reviews of FGMs can be found in [1,2,25–27]. Typical parameters of FGMs are shown in Table1. Referring to Table1, the magnetic field range, noise level and linearity allows FGMs to measure the Earth’s magnetic field, between 25 and 65 µT, and the sensitivity allows a measurable output with a 5 V power supply and simple signal processing. Moreover, the low temperature coefficient means that FGMs can be used when drilling wells with depths up to 20,000 feet, where temperatures can be as high as 230 ◦C. Several papers have demonstrated the stability of FGMs in a 180–250 ◦C temperature range [28,29]. Not only do FGMs have excellent noise characteristics compared with other magnetic sensors but they can be constructed easily according to well established design principles at low cost.
Table 1. Typical parameters of fluxgate magnetometers.
Field Range Sensitivity Linearity Temperature Coefficient Size Noise Frequency √ 10 pT–2 mT 20–50 mV/µT <10 ppm 0.25 nT/◦C mm 15 pT/ Hz 10 kHz
The working principle of an FGM in its simplest form can be explained with reference to Figure1. An FGM consists of two coils, an excitation and a pick-up coil, wound around a ferromagnetic rod as shown in Figure1(ai,bi). The ferromagnetic rod is driven to saturation when a large alternating current (AC) is applied to the excitation coil by a waveform generator and a magnetic flux density (B) is induced in the rod, as shown in Figure1(ai). As the rod is driven into saturation, as shown in Figure1(bi), it becomes progressively more difficult for magnetic field ( H) lines to pass through the rod and induce a B. This reluctance of the rod is sensed by the pick-up coil, which creates changes in the voltage of the pick-up coil. Since the rod is driven to saturation twice during each excitation cycle, the second harmonic of the output voltage of the pick-up coil is extracted by phase demodulation circuitry. When the FGM is in the presence of an external H (Hext), such as the Earth’s magnetic field, the induced B is distorted. This distortion is sensed by the pick-up coil causing a change in the output voltage; the magnitude corresponds to the strength of Hext and the phase to the orientation of the Hext. The magnetic hysteresis (B-H) curve in Figure1(aii) shows the operation of the FGM in the linear region during excitation, and the B-H curve in Figure1(bii) shows the operation of the FGM in saturation. The sensitivity of the FGM depends on the B-H curve, where a steeper magnetizing curve relates to a more sensitive FGM. The power consumption of an FGM depends on the coercivity and saturation fields as shown in Figure1(aii,bii). Lower saturation coercivity fields mean lower magnetic fields, and hence lower excitation currents and power, required to drive the rod to saturation and back to zero after being saturated. The frequency response of an FGM depends on the time lag between the application of the excitation field and the response of the ferromagnetic rod. Sensors 2017, 17, 2384 3 of 32 Sensors 2017, 17, 2384 3 of 32
(i) (i)
Magnetic field lines
Excitation coil AC excitation waveform
Ferromagnetic rod
Pick-up coil V Voltage output V
(ii) Not Saturated (ii) Saturated B B Working area Working area Coercive field H H
Working area
Saturation field
(a) (b)
FigureFigure 1. (a )1. Principle (a) Principle operation operation of of a a fluxgate fluxgate magnetometermagnetometer (FGM (FGM).). (i) ( Applicationi) Application of an of AC an current AC current and the induction of a magnetic flux density (B) in the rod and (ii) the corresponding B-H curve and the induction of a magnetic flux density (B) in the rod and (ii) the corresponding B-H curve showing the grey area the FGM operates in during this excitation phase; (b) (i) The FGM in saturation showing the grey area the FGM operates in during this excitation phase; (b)(i) The FGM in saturation mode where B has saturated and magnetic field (H) lines do not converge to the rod resulting in (ii) B H modethe where FGM operatinghas saturated in the saturated and magnetic area of the field B-H ( curve.) lines do not converge to the rod resulting in (ii) the FGM operating in the saturated area of the B-H curve. In reality, for a single ferromagnetic rod, the pick-up coil will sense both the excitation voltage Inas reality,well as the for output a single voltage. ferromagnetic This makes rod, it challenging the pick-up to coil filter will out sense the second both theharmonic, excitation obtain voltage its as well asph thease and output rectify voltage. it to obtain This makesvoltage itproportional challenging to to the filter magnitude out the of second the external harmonic, field. obtainIn order its to phase overcome this challenge two variants of the FGM, a Vacquier-type FGM, shown in Figure 2(ai), and and rectify it to obtain voltage proportional to the magnitude of the external field. In order to overcome a ring-core FGM, shown in Figure 2(aii), are commonly used [26,30–32]. Taking Figure 2a into this challenge two variants of the FGM, a Vacquier-type FGM, shown in Figure2(ai), and a ring-core account, the wires are wound on both rods in opposite directions to each other in a Vacquier-type FGM,FGM shown and, in similarly Figure2 for(aii), a ring are- commonlycore FGM, the used windings [ 26,30 are–32 such]. Taking that on Figure one half2a intoof the account, core they the are wires are woundin the opposite on both direction rods in oppositeto the other directions half. When to an each excitation other in current a Vacquier-type is applied, the FGM induced and, B similarly in one for a ring-corerod or half FGM, of the core windings will have are the such opposite that on polarity one half to ofB in the the core second they rod are or in the the other opposite half of direction the to thecore. other This half. results When in a annet excitationmagnetization current of zero is applied,and an output the inducedvoltage ofB zeroin one at the rod pick or-up half coil. of For the core will haveexample, the oppositeFigure 2( polaritybi,bii) show to B thatin the when second an exc roditation or the current other (orange half of the waveform) core. This is appliedresults, in B a net magnetizationincreases with ofzero the current and an and output reaches voltage saturation of zero at the at peak the pick-upof the excitation coil. For current. example, The B Figure produced2(bi,bii) showfro thatm both when rods an and excitation both sides current of the (orangecores are waveform) mirror images is applied,of each otherB increases along the with x-axis the (blue current and and green waveforms) resulting in a net B of zero [33]. The voltages from both rods and sides of the core reaches saturation at the peak of the excitation current. The B produced from both rods and both sides at the pick-up coil are also mirror images along the x-axis, are proportional to the rate of change of B, of the cores are mirror images of each other along the x-axis (blue and green waveforms) resulting in a net B of zero [33]. The voltages from both rods and sides of the core at the pick-up coil are also mirror images along the x-axis, are proportional to the rate of change of B, and increase and then reach SensorsSensors 20172017,, 1717,, 23842384 44 ofof 3232 and increase and then reach zero at saturation as the rate of change of B is zero at saturation. zeroHowever, at saturation when there as the is an rate Hext of, the change rod or of theB is half zero-core at saturation.that is generating However, an H when in the there same is direction an Hext, theas H rodext takes or the longer half-core to come that out is generating of saturation, an H thereforein the same the rod direction or the ashalfHext-coretakes generating longer to an come H in outthe ofopposite saturation, direction therefore comes the out rod of or saturation the half-core sooner. generating This can an beH seenin the in opposite Figure 2 direction(biii) from comes the short out ofand saturation long saturation sooner. times This canfor each be seen rod in or Figure half-core2(biii) every from half the cycle short of and the longwaveform. saturation This times creates for a eachnet change rod or half-corein B in the every pick half-up cyclecoil (black of the waveform), waveform. Thiswhich creates induces a net a voltage change in Bthein pick the pick-up-up coil coil(purple (black waveform), waveform), as whichshown inducesin Figure a voltage2(biv). A in clear the pick-up amplified coil waveform (purple waveform), (red waveform) as shown can be in Figureobtained2(biv). by tuning A clear the amplified pick-up waveform coil. (red waveform) can be obtained by tuning the pick-up coil.
Ferromagnetic ring (i) (ii) Excitation coil Ferromagnetic Excitation rod coil V
Pick-up V coil Pick-up coil
Rod 1 Rod 2 Side 1 Side 2 Vacquier type Ring-core type (a)
(i) Vexcitation Excitation Waveform
(ii) B No external magnetic field (Hext = 0) B generated by each Rod 1/Side 1 of Core rod or side of the core (No external field) Rod 2/Side 2 of Core
(iii) B External magnetic field B generated by each (Hext ≠ 0) rod or side of the core (External field) Net change in B at the pick-up coil
(iv) Shorter saturation times Vpick-up Induced voltage Voltage at pick-up coil Tuned voltage due to external field
Time
(b) FigureFigure 2.2. ((a)Variants)Variants ofof anan FGM.FGM. ((ii)) Vacquier-typeVacquier-type FGMFGM withwith wireswires woundwound onon bothboth rodsrods 11 andand 22 inin oppositeopposite directionsdirections to to each each other; other (; ii(ii)) Ring-core Ring-core type type FGM FGM where where the the windings windings on on side side 1 of1 of the the core core is inis oppositein opposite direction direction to side to side 2; (b 2;)( (ib)) Application (i) Application of an of excitation an excitation waveform waveform (orange (orange waveform) waveform) to (a)( toi) ( ora) ((ai)() orii); (a (ii) )(ii In); the(ii) absence In the absence of an external of an magneticexternal magnetic field (Hext ),fieldB induced (Hext), B in induced rod 1/side in 1rod (blue 1/side waveform) 1 (blue iswaveform) opposite in is polarityopposite to in B polarity induced to in B rod induced 2/side in 2 rod (green 2/side waveform), 2 (green waveform), so net magnetization so net magnetization and voltage (V)and induced voltage at (V the) inducedpick-up coil at theis zero; pick (iii-up) In coil the is presence zero; ( ofiii) an InH ext thethe presence rod/core of generating an Hext the a magnetic rod/core fieldgenerating in the a same magnetic direction field asin Htheext samehave direction a shorter as saturation Hext have timea shorter and saturation there is a nettime change and there in B is in a thenet pick-upchange in coil B in (black the pick waveform);-up coil (black (iv) This waveform) net change; (iv) in This B induces net change a voltage in B induces in the pick-upa voltage coil in (purplethe pick waveform).-up coil (purple A clear waveform). amplified A waveform clear amplified (red waveform) waveform can (red be obtainedwaveform) by can tuning be obtained the pick-up by coiltuning [33 ].the pick-up coil [33].
MoreMore recently, recently, miniature miniature FGMs FGMs have have been been fabricated fabricated using using complementarycomplementary metal-oxide-metal-oxide- semiconductorsemiconductor (CMOS),(CMOS), micro-fabricationmicro-fabrication andand printedprinted circuitcircuit boardboard PCBPCB methodsmethods [[3434––3737].]. Their size, compactness,compactness, low low power powe consumptionr consumption and theand possibility the possibility of integration of integration with electronics with electronics into integrated into circuitintegrated (IC) circuit chips ( makeIC) chips them make ideal them candidates ideal candidates for portable for portable devices. devices. However, However, one of theone majorof the major drawbacks of miniature FGMs is the limited number of turns possible in the excitation and
Sensors 2017, 17, 2384 5 of 32 drawbacks of miniature FGMs is the limited number of turns possible in the excitation and pick-up coilsSensors during 2017 the, 17, 2384 fabrication process. The limited number of turns in the excitation coil in a miniature5 of 32 FGM results in the rod or core not being properly saturated, and in a pick-up coil leads to lower pick-up coils during the fabrication process. The limited number of turns in the excitation coil in a sensitivities than traditional FGMs. Higher amplitudes and frequencies of the excitation current can miniature FGM results in the rod or core not being properly saturated, and in a pick-up coil leads to be usedlower to sensitivities compensate than for traditional this drawback FGMs. but Higher at the amplitudescost of higher and power frequencies consumption. of the excitation Moreover, comparedcurrent tocan traditional be used to simply-wound compensate for FGMs this drawback there is a but higher at the cost cost associated of higher with power microfabrication consumption. of miniatureMoreover, FGMs. compared to traditional simply-wound FGMs there is a higher cost associated with microfabrication of miniature FGMs. 2.2. Navigating a Well Using Magnetometers 2.2.In Navigating directional a drilling,Well Using the Magnetometers well is deviated from a vertical trajectory to a trajectory that is kept within prescribedIn directional limits drilling of azimuth, the well and is inclinationdeviated from to reach a vertical a final trajectory landing to point a trajectory as shown that in is Figure kept 3a. Directionalwithin prescribed drilling is limits performed of azimuth so that and theinclination final landing to reach point, a final typically landing apoint reservoir, as shown can in be Figure reached when3a. it Directional is below a populated drilling is performedarea or areas so inaccessible that the final due landing to obstructions point, typic suchally as a mountainsreservoir, can or rivers. be Directionalreached when drilling it is allowsbelow a multiple populated wells area or to areas be drilled inaccessible from adue single to obstructions vertical well such and as mountains significantly increasesor rivers. the accessDirectional and exposuredrilling allows to a reservoir multiple compared wells to be with drilled vertical from drilling. a single As vertical Figure well3b shows, and directionalsignificantly drilling increases is a three the dimensional access and exposure processwhere to a reservoir the azimuth compared is the deviation with vertical from drilling. the magnetic As Figure 3b shows, directional drilling is a three dimensional process where the azimuth is the north in the horizontal plane, and the inclination of the well is the angle the well deviates from deviation from the magnetic north in the horizontal plane, and the inclination of the well is the angle the vertical direction, represented as zero degrees. The azimuth is defined as the orientation of the well, the well deviates from the vertical direction, represented as zero degrees. The azimuth is defined as measured clockwise with respect to the magnetic north. The line along the vertical direction is always the orientation of the well, measured clockwise with respect to the magnetic north. The line along the parallelvertical to thedirection Earth’s is gravitationalalways parallel field. to the The Earth toolface,’s gravitational as shown field. in FigureThe toolface,3b, is theas shown angle thein Figure drill bit rotates3b, is on the the angle drilling the drill plane bit from rotates an on initial the drilling reference plane point. from an initial reference point.
Magnetic North Azimuth
(a) Projection of the well
Inclination angle
(b) Vertical direction
Azimuth
Magnetic North
Drill Toolface bit Inclination angle angle AA Top view A
Drilling Drill bit plane A rotation Drilling direction
FigureFigure 3. ( a3.) ( Azimutha) Azimuth and and inclination inclination when when drillingdrilling a directional directional well; well; (b (b) The) The azimuth azimuth of a of directional a directional well is the deviation from the magnetic north and the inclination is the deviation from the vertical well is the deviation from the magnetic north and the inclination is the deviation from the vertical direction of the well. The toolface is the angle the drill bit rotates on the drilling plane from an initial direction of the well. The toolface is the angle the drill bit rotates on the drilling plane from an initial reference point. reference point.
Sensors 2017, 17, 2384 6 of 32
Sensors 2017, 17, 2384 6 of 32 The earliest directional drilling tools, such as lowering an acid bottle into a well to etch an acid ring on theThe bottle earliest and directional the Totco drilling mechanical tools, driftsuch recorder,as lowering only an measuredacid bottle the into inclination a well to etch of a an well acid [38 ]. Magneticring on single the bottle and multi-shotand the Totco surveys mechanical were drift the firstrecorder, instruments only measured to measure the inclination both inclination of a well and azimuth,[38]. Magnetic and consisted singleof and a magneticmulti-shot compass, surveys were inclinometer the first instruments and a camera to controlledmeasure both by inclination an electronic timerand [39 azimuth,]. These and single consisted and multi-shot of a magnetic devices compass, had to inclinometer be run on wireline and a camera down controlled a well or dropped by an downelectronic the drillstring timer [39]. assembly These single and retrieved and multi after-shot pulling devices the had drillstring to be run outon wireline of the well. down a well or dropped down the drillstring assembly and retrieved after pulling the drillstring out of the well. Early well deviating methods included setting whipstocks, jetting tools and build, drop and Early well deviating methods included setting whipstocks, jetting tools and build, drop and pendulum BHA assemblies [38,40–44]. However, the advent of the downhole mud motor and the rapid pendulum BHA assemblies [38,40–44]. However, the advent of the downhole mud motor and the development of compact, rugged sensors along with the mud pulse telemetry method of transmitting rapid development of compact, rugged sensors along with the mud pulse telemetry method of datatransmitting from downhole data from to the downhole surface allowedto the surface the azimuth allowed andthe azimuth inclination and toinclination be measured to be measured in real-time. Thein most real established-time. The mostmethod established of using methodthis measurement of using this while measurement drilling (MWD) while technique drilling (MWD) is using the configurationtechnique is using shown the in configuration Figure4a, which shown has in a Figure bent-housing 4a, which motor, has a several bent-hous stabilizersing motor, and several a MWD unit.stabilizers The bent-housing and a MWD motor unit. has The a hydraulic bent-hous motoring motor that ishas driven a hydraulic by the drillingmotor that fluid is flowingdriven by through the the drillingdrilling assembly.fluid flowing through the drilling assembly.
(a) Stabilizer (b)
Drillpipe Drill pipe
Triaxial FGMs Hz
MWD Hx √ Hx2+Hy2+Hz2 Drilling
assembly Hy Gz Triaxial Bent-housing accelerometers motor
Gx
√ Gx2+Gy2+Gz2
Gy
Drill bit
(i) Sliding Mode (ii) Rotating mode
Drill bit and drilling Drill bit rotation assembly rotation
(c)
FigureFigure 4. (4.a )(a Drilling) Drilling assembly assembly for directional directional drilling drilling with with an MWD an MWD unit unitconsisting consisting of FGMs of and FGMs andaccelerometers, accelerometers, as asshown shown in ( inb), (tob), obtain to obtain azimuth azimuth and inclination and inclination measurements measurements of the well, of a the bent well,- housing motor, as shown in (c) (i), that initiates the trajectory of the well being drilled, and stabilizers a bent-housing motor, as shown in (c)(i), that initiates the trajectory of the well being drilled, that allow side force to be generated at the bit. Once the desired trajectory is obtained the whole and stabilizers that allow side force to be generated at the bit. Once the desired trajectory is obtained drilling assembly and the bent-motor drills ahead as shown in (ii). the whole drilling assembly and the bent-motor drills ahead as shown in (ii).
Sensors 2017, 17, 2384 7 of 32
The MWD unit includes tri-axial FGMsand tri-axial accelerometers, as shown in Figure4b and the mud-pulse telemetry system (not shown), which is located above the fluxgate magnetometers and accelerometers. The stabilizers are used to control contact with the wellbore and form a fulcrum with the hydraulic motor behind it acting as a lever, thus allowing side force to be generated at the bit. The bend is adjusted according to the angle of the well being drilled and is normally set anywhere between 0◦ and 2◦ but sometimes as high as 3◦. Initially only the hydraulic motor powers the drill bit and there is no rotation of the drilling assembly above the drill string, as shown in Figure4(ci). The motor can be oriented in any desired manner to build angle, drop angle or turn. Once the desired trajectory of the well is attained the entire drilling assembly and the bit are rotated to drill straight ahead as shown in Figure4(cii). The Earth’s magnetic field has a different strength and orientation at every location on Earth and this field is measured using tri-axial FGMs while the inclination of a well is obtained by measuring the gravitational field by tri-axial accelerometers. FGMs are used to measure the toolface when the well is vertical (0◦ inclination) as the gravitational field will be constant, and accelerometers are used to measure the toolface when the well is horizontal (90◦ inclination). Any toolface measurement between an inclination of 0◦ and 90◦ is performed by both FGMs and accelerometers. Generally the directional MWD crosses over from magnetic tooolface to gravitational toolface at angles from 3◦ to 5◦. The position P of the drill bit in a well being drilled can be obtained at any time in terms of the magnetic field, inclination and toolface as shown below [45]: