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Lin - 2020
Lin - 2020
Abstract— The orientation module of MWD tool provides the and safety. Exiting the casing shoe of a partially completed
critical drill bit orientation information, including azimuth, vertical well to start a new lateral section can be particularly
inclination and toolface in order to control the path of wellbore. problematic, as this may require drilling 30 or more meters
Although high end navigation grade gyroscope can meet the away from the casing before the MWD magnetometer provides
accuracy requirement for azimuth finding, the requirements of reliable measurements. Significant expense may be incurred if
cost, size and reliability under harsh environment have largely the trajectory veers off course and the well must be plugged
limited the deployment of gyroscopes in MWD tools. To back and re-drilled [2].
overcome these constraints, GE Research has developed a low
cost, MEMS based Multi-Ring Gyroscope (MRG) capable of
azimuth-seeking in MWD applications at 300oC. The MRG
prototype has been demonstrated to achieve angular random
walk (ARW) better than 0.003 deg/rt(hr) and bias instability of
0.01 deg/hr, capable of meeting azimuth finding accuracy better
than 0.25 deg. It has also been tested to remain fully operational
at 300 oC.
Directional drilling is the practice of steering a wellbore Azimuth seeking by MEMS gyroscopes can overcome the
along a predefined trajectory leading to a subsurface target [1]. limitations of magnetic interference in MWD tools. MEMS
The method allows for drilling from remote surface locations Gyroscope-based orientation tools measure the earth rotation
into otherwise inaccessible reservoirs and enables higher rate vector in order to calculate azimuth, which is also referred
energy output. Knowledge of the drill bit orientation and to as gyrocompassing. For azimuth seeking operation, the
along-hole depth is the essential feedback used to survey and gyroscope is mounted on a rotary platform which physically
control the path of the wellbore. Similar to the roll, pitch and rotates the horizontal orientation of the gyroscope’s sensitive
yaw angles used in navigation, the drill bit attitude, including axis with respect to the north. This method is referred to as
azimuth (deviation from the North direction in the horizontal carouseling or maytagging [3]. The azimuth is calculated from
plane), inclination (deviation from the vertical direction, or the phase of the sinusoidal gyroscope output from the
pitch angle) and toolface (roll angle), will need to be measured projection of Earth rate when the platform rotates. This method
to control the quality of the drilling process. This is currently eliminates the bias and scale factor errors from the azimuth
done by the orientation module in the measurement-while- calculation. Fig. 2 shows our experimental work to establish
drilling (MWD) tool. Fig. 1 shows an example of a commercial the feasibility of MEMS gyrocompassing using a commercial
orientation tool which uses accelerometers and magnetometers MEMS gyroscope to achieve 1o azimuth uncertainty measured
to measure orientation. at 85oC. Our experiment shows the potential of MEMS inertial
Unfortunately, magnetometer-based orientation tools are sensors in meeting MWD targets. Oilfield testing results using
susceptible to magnetic interference due to the anomalies in the MEMS gyroscopes in MWD tools have also been reported by
surrounding environment or by components of the drill string the other researchers [4, 5].
itself. Poor survey accuracy due to magnetic interference may It is important to recognize the harsh environmental factors
compromise well quality and can occasionally create hazardous of directional drilling. These include depth of oil and gas wells
drilling conditions. Inaccurate calculation of the trajectory range from 3,500 to 30,000 feet, temperature as high as 300o C,
increases the chance of colliding with an adjacent well or its mechanical shock up to 2000G, extreme conditions including
completion fractures compromising production, well control
tension, corrosion and cyclic loading and damaging gases. II. MULTI-RING GYROSCOPE DESIGN
Macro-scale systems such as hemispherical resonant gyroscope
(HRG), ring laser gyroscopes (RLG) or fiber optic gyroscopes A. North Finding Consideration
(FOG) tend to be bulky and expensive, adversely affecting the Gyrocompassing requires repeatable and stable
economics of the service and preventing the tools from being measurements of extremely low angular rates (fractions of the
used in narrower holes. Many of these systems also suffer Earth’s rate). For example, 0.5o azimuth accuracy at the 45o
from poor thermal performance and limited lifetime when latitude with a 5 minute carouseling time will require a gyro-
exposed to the shock and vibration of the drilling process. The scope with angular random walk (ARW) less than 0.01o/√hr
MEMS gyroscopes, on the other hand, suffer from large long- and bias instability less than 0.1o/h which is well into the realm
term bias drift, which is further exacerbated by high operating of short-term navigation grade. To achieve these performance
temperature and high mechanical shock and vibration. Our targets, GE Research has invented a new design called
survey of the published MEMS devices has led to the multiple-ring gyroscope (MRG) [7]. MRG is an axisymmetric
discovery that no existing commercial MEMS gyroscopes can structure utilizing multiple concentric rings as the proof mass,
reliably operate at 300oC for 1000+ hours while maintaining as shown in Fig. 3. Compared with disk resonator gyroscopes
the accuracy needed for the north seeking operation [6]. This (DRG) [8], the MRG has much lower mechanical stiffness
is a critical technology that needs to be invented and which allows for higher drive amplitude, resulting in reduced
developed. ARW noise. Compared to vibratory ring gyroscopes [9], the
MRG has a higher performance entitlement due to its larger
modal mass and improved sensitivity. Compared with tuning
fork gyroscopes, the MRG is also inherently more robust
against vibration and shock at downhole drilling conditions due
to its uniformly distributed mass, axisymmetric structure and
much higher frequency for the bending or translational modes.
Fig. 6. GE Research Polaris flow features TSV and wafer level vacuum seal Compared with the consumer-grade and automotive-grade
gyroscopes, navigation-grade gyroscopes often start at a much
The Polaris process starts with two SOI wafers. The first lower volume demand and require more iterative steps of
SOI wafer is the device wafer where the MEMS structures are process and design optimization. The Polaris flow strives to
formed through high aspect ratio silicon etching on a bulk SOI provide the simplest inertial MEMS flow with wafer-level
wafer. The deep reactive ion etching (DRIE) process has been vacuum sealing and TSV capabilities, making it suitable for
specifically optimized for good dimensional control and quick prototyping and low-to-mid volume production. The
symmetry (mismatch <100ppm), which is critical for MRG development is a good example to showcase how the
minimizing gyroscope frequency split and cross coupling Polaris flow, as a platform technology, can accelerate the
errors. Fig. 6 shows a 3um wide trench etched on 100um thick innovation and adoption of navigation-grade inertial sensors.
device layer. The second SOI wafer forms the cap. This cap
wafer contains the critical TSV technology. In the Polaris
process, a single crystal silicon via is formed with a trench etch IV. MRG CHARACTERIZATION
and dielectric refill. The via itself is the parent silicon. The The characterization of fabricated MRG starts with testing
etched trench forms the insulator. The Polaris TSV process has un-sealed devices in vacuum probe station with a high
a few key advantages. It enables direct bonding between the temperature heater stage which is capable of testing to 300oC,
TSV wafer and device wafer without the need of intermediate as shown in Fig. 8. A similar test procedure was devised for
materials. Unlike a ‘drill and fill’ approach in which the testing wafer level sealed parts on the heated stage of a wafer
geometry of the shape is highly limited, The Polaris TSV can probe station. By testing the un-sealed MRG devices under
vacuum, and the wafer-level sealed devices under similar
electrical and temperature conditions, the actual vacuum level
inside the device cavity can be established.
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