Erosion prediction for downhole tools

Patent metadata

Field	Value
Publication number	US-12037852-B2
Application number	US-202217858131-A
Country	US
Kind code	B2
Filing date	Jul 6, 2022
Priority date	Jul 6, 2021
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

Downhole monitoring systems are described. The systems include a downhole string disposed in a borehole, the string having a downhole tool and the borehole has fluid therein. A sacrificial electrical sensor element is arranged in or on the string. The sacrificial electrical sensor element includes magnetic material at least partially exposed to the fluid and at least one coil arranged in magnetic communication with the magnetic material. A controller is configured to provide an electrical current into the coil, measure an electrical property of the coil that is based on the magnetic material in magnetic communication with the coil, and determine a wear state of the downhole tool based on the measured electrical property.

First claim

What is claimed is:

1. A downhole monitoring system comprising:
a downhole string disposed in a borehole, the downhole string comprising a downhole tool, wherein the borehole has fluid therein;
a sacrificial electrical sensor element in or on the downhole string, wherein the sacrificial electrical sensor element comprises:
magnetic material at least partially exposed to the fluid, the magnetic material selected to be eroded by the fluid; and
at least one coil arranged in magnetic communication with the magnetic material; and
a controller configured to:
provide an electrical current into the at least one coil,
measure an indicator of an inductance of the at least one coil, wherein the indicator of the inductance of the at least one coil is configured to change due to an erosion of the magnetic material in magnetic communication with the at least one coil by the fluid; and
determine a wear state of the downhole tool based on the measured indicator of the inductance.

2. The downhole monitoring system of claim 1 , wherein the controller is configured to:
compare the measured indicator of the inductance against a predetermined value of a wear threshold of the downhole tool, and
generate a notification regarding the wear state of the downhole tool when the wear threshold is met.

3. The downhole monitoring system of claim 1 , wherein the sacrificial electrical sensor element has two coils, wherein a first coil is arranged in magnetic communication with a first magnetic material exposed to the fluid and a second coil is arranged in magnetic communication with a second magnetic material protected from the fluid.

4. The downhole monitoring system of claim 3 , wherein the controller is configured to compare a measured indicator of an inductance of the first coil with a measured indicator of an inductance of the second coil.

5. The downhole monitoring system of claim 3 , wherein the first magnetic material is arranged on an upstream side of the sacrificial electrical sensor element relative to a flow of the fluid in the borehole and the second magnetic material is arranged on a downstream side of the sacrificial electrical sensor element relative to the flow of the fluid in the borehole.

6. The downhole monitoring system of claim 3 , wherein the second magnetic material is arranged within the downhole tool.

7. The downhole monitoring system of claim 3 , wherein the controller includes a first oscillator circuit electrically connected to the first coil, a second oscillator circuit electrically connected to the second coil, and a frequency comparison unit configured to compare a frequency measurement from the first oscillator circuit and the second oscillator circuit.

8. The downhole monitoring system of claim 1 , wherein the magnetic material forms a housing and the at least one coil is arranged inside the housing.

9. The downhole monitoring system of claim 8 , wherein the sacrificial electrical sensor element comprises a non-magnetic support shell configured to provide structural support to the at least one coil.

10. The downhole monitoring system of claim 1 , wherein the indicator of the inductance is at least one of a magnetic flux of the at least one coil or a voltage and a phase of an electrical signal of the at least one coil.

11. A method for monitoring components disposed in a downhole environment, the method comprising:
disposing a downhole string in a borehole, the downhole string comprising a downhole tool, wherein the borehole has fluid therein, the downhole string comprising a sacrificial electrical sensor element in or on the downhole string, wherein the sacrificial electrical sensor element comprises magnetic material at least partially exposed to the fluid and at least one coil arranged in magnetic communication with the magnetic material, the magnetic material selected to be eroded by the fluid;
supplying an electrical current into the at least one coil;
measuring an indicator of an inductance of the at least one coil, wherein the indicator of the inductance of the at least one coil is configured to change due to an erosion of the magnetic material in magnetic communication with the at least one coil by the fluid;
determining a wear state of the downhole tool based on the measured indicator of the inductance; and
performing an operational action based on the wear state.

12. The method of claim 11 , wherein:
the operational action includes replacing the downhole tool in the downhole string.

13. A method for monitoring components disposed in a downhole environment, the method comprising:
disposing a downhole string in a borehole, the downhole string comprising a downhole tool, wherein the borehole has fluid therein, the downhole string comprising a sacrificial electrical sensor element in or on the downhole string, wherein the sacrificial electrical sensor element comprises magnetic material at least partially exposed to the fluid and at least one coil arranged in magnetic communication with the magnetic material;
supplying an electrical current into the at least one coil;
measuring an electrical property of the at least one coil, wherein the electrical property of the at least one coil is based on the magnetic material in magnetic communication with the at least one coil;
determining a wear state of the downhole tool based on the measured electrical property; and
performing an operational action based on the wear state,
wherein the sacrificial electrical sensor element has two coils, wherein a first coil is arranged in magnetic communication with a first magnetic material exposed to the fluid and a second coil is arranged in magnetic communication with a second magnetic material protected from the fluid, the method comprising:
comparing an electrical property of the first coil with an electrical property of the second coil.

14. A method for monitoring components disposed in a downhole environment, the method comprising:
disposing a downhole string in a borehole, the downhole string comprising a downhole tool, wherein the borehole has fluid therein, the downhole string comprising a sacrificial electrical sensor element in or on the downhole string, wherein the sacrificial electrical sensor element comprises magnetic material at least partially exposed to the fluid and at least one coil arranged in magnetic communication with the magnetic material;
supplying an electrical current into the at least one coil;
measuring an electrical property of the at least one coil, wherein the electrical property of the at least one coil is based on the magnetic material in magnetic communication with the at least one coil;
determining a wear state of the downhole tool based on the measured electrical property; and
performing an operational action based on the wear state,
wherein the sacrificial electrical sensor element has two coils, wherein a first coil is arranged in magnetic communication with a first magnetic material exposed to the fluid and a second coil is arranged in magnetic communication with a second magnetic material protected from the fluid, and a first oscillator circuit is electrically connected to the first coil and a second oscillator circuit is electrically connected to the second coil, the method comprising:
comparing a frequency measurement from the first oscillator circuit and the second oscillator circuit.

15. A downhole monitoring system comprising:
a downhole string disposed in a borehole, the downhole string comprising a downhole tool, wherein the borehole has fluid therein;
a sacrificial electrical sensor element in or on the downhole string, wherein the sacrificial elec

Assignees

• Kruspe Thomas
• Rottengatter Peter
• Baker Hughes Oilfield Operations Llc

Inventors

• Kruspe Thomas
• Rottengatter Peter

Classifications

• E21B47/006 Primary

  Detection of corrosion or deposition of substances · CPC title

• G01R19/00

  Arrangements for measuring currents or voltages or for indicating presence or sign thereof (G01R5/00 takes precedence; for measuring bioelectric currents or voltages A61B5/24) · CPC title

• G01V3/28

  using induction coils · CPC title

• E21B12/02 Primary

  Wear indicators · CPC title