Acoustic MEMS Transducers: Look Ahead of the Bit and Geopressure Monitoring

Abstract

This paper describes the design and implementation of Acoustic Micro Electro Mechanical Systems (hereinafter referred to asA-MEMS)working in fluid-coupling mode for HP/HT specifications relevant to downhole applications such as drilling, well and reservoir monitoring. Many cutting edges applications ofA-MEMS in Oil & Gas industry are envisaged. The current work refers to the case study of a "Look Ahead of the Bit"/geopressure monitoring technique (hereinafter referred to asPPM) developed by the authors. A–MEMS with magnetic shuttle transducers have been designed so that they are not affected by environmental pressure like piezoelectric devices commonly used in MWD commercial sonic tools, which are impaired by volumetric shrinking/expansion working principle. This performance is also achieved by embedding an environmental pressure compensator tuned in the whole working bandwidth to grant pressure balance even with oscillatory motion at sonic frequencies (up to 5 kHz). Transmitter acoustic power and receiver sensitivity have been optimized in a bandwidth between 500 and 3500 Hz. A couple of A–MEMS prototypes have been built and successfully tested by using an oil filled pressure vessel at downhole T–P conditions (200 °C, 700bar) and an ad-hoc measurement setup including force, displacement, temperature sensors, transmitter (TX) driver, receiver (RX) lock-in amplifier and anacquisition system. Moreover, modal analysis at typical drilling conditions has been carried out by Stewart platform. Shock up to 1000 g and random vibrations up to 12 g RMS in 5 ÷400 Hz bandwidth have been tested. A–MEMS performance have turned out to be consistent with theoretical model predictions andhave exhibited robustness to T P variations and applied structural stress. PPM method has been validated through a triaxial compression cell in a rock mechanics laboratory, implementing a lab scale scenario with a cap rock located above a permeable rock, undergoing all geopressures of interest. However, piezo transducers used in the experiment underwent a significant failure/damage rate along with performance degrading at pressure increasing. These observations confirmed and motivated the need for A-MEMS technology development in downhole applications.