Report on MWD Experimental Downhole Sensors
Donald S. GrOSSO, SPE, TeIeco OilfieldServfcesInc.
Jean C. Rnyntd, SPE, So.. Natl. ElfAquitaine
Dennis Rader, SPE, Teleco OilfieldSer#ices Inc.
Summary
Measurement while drilling (MWD) provides a means
for monitoring drilling and formation parametem as drill-
ing progresses, The technique, based on the use Of ad-
vanced dow”hole sensor and telemet~ technology,
makes possible the red-time acquisition of data that was
previously impossible without stopping the drilling
operation. Some downhole data, such as weight and
torque on bit (WOB and TOB) can be obtained onfy
wh~e drilling.
In Summer 1976, Teleco Oilfield Services began an
experimental pmgmm to demonstrate the feasibility and
usefulness of a multisensory MWD tool for reaf-time
measurement of drifIing mechanics, formation evalua-
tion, and well-control pammeters. A package incor-
porating six sensors was designed and implemented in a
downhole tool capable of transmitting data to the surface
by mans of mud-pulse telemetry.
In this paper we discuss the experimental 6-sensor tool
and representative results obtained in a series of 12 field
tests in various parts of the world, both onshore and
offshore.
Introduction
The MWD tool was introduced in Aug. 1976 on a
limited basis. It was desiemed to provide the dmctiond-
drilling industW with real-time measurements of hole
deviation, azimuth, and tool facing. Full commercial
directional service was made available in the Gulf of
Mexico and the Noti Sea in Sept. 1978. In a pamflel ef-
fort begun in 1976, an experimental system was built to
0,4S.273SIWO05, .0058 $00.26 –
COPyright ,9s3 Society d Petrdwm Englnem of AIME
MAY1983
demonstmte the broader potential of downhole MWD
technology for enhancing the safety and efficiency of
drilling while simultaneously obtaining formation-
evaluation data. Two prntotype MWD tools incor-
porating six downhole sensors and using mud-pulse
telemetfy were built. More than 1,200 hours of con-
tinuous mud-pulse data transmission we? accumulated
in the field test progmm.
Telemetry System
Mud-pulse telemet~ is a wireless means of com-
municating data from downhole to the surface. Informa-
tion in the form of binary bits is communicated through a
sequence of pressure pulses generated in the mud column
within the drillpipe by a valve located in a special sub
near the bh. Thk information, in the form of pressure
waves, propagates through the drilling mud and is
detected and dispIayed at the surface.. This technique imp-
oses no restrictions on the drilling operation, is mgged,
reliable, safe, and only marginally affected by mud com-
position or depth. -
So far, .MWD technology has been applied primarily
to directional surveying. Its use in other applications,
such as formation evaluation and drilling eftlciency, of-
fers great prnmise to the oil and gas well drilling in-
dustry. In the balance of this paper, some of these ap-
plications are discussed on the basis of an extensive
series of tests with the experimental six-sensor MWD
tool. Additional discussions of MWD technology. and
applications are found in Refs. 1 through 4.
The essential elements of the telemetry system consist
of the transmitter and surface receiving equipment.
S99
 TABLE l–RANGE AND RESOLUTION OF DOWNHOLE MEASUREMENTS

Parameter
Formation radiation, API units
Boreholepressure, psi
Borehole temperature, ‘F
Mud resistivity,Q-m
Weight on bit, Ibf
Rangs
0 to 200
o to 15,000
77 to 257
0.01 to 5.0
O tO 80,000
Resolution and
Repeatability
.1 ~o”nt -
15
0.1
0.2% of reference mud
80
I
Torque on bit, lbf-ft 0 to 50,000 50

Transmitter and Surface Receiver

The downhole assembly (Fig. 1) incorpomtes a mud-
pulse transmitter and a sensor package mounted in a
. Mud FIOW 34-ft-long drill coUar located above the bk.
The transmitter produces a smnll pressure puke in the
flowing mud column, inside the drillshing by means of a
valve that imposes a vcriable restriction in the “mud
stream. The valve is driven by hydraulic power
genernted downbole by a turbine mounted in the same
— Transmitter
package. The valve is electrically controlled and is
modulated with binary information generated in the sen-
— Generatcf sor package.
A signal detection and display unit is Iocatcd at the
surface to receive the mud-pulse telemet~ data, to
decode it, and to display the resulting information. The
— T’urbine unit consists of a pressure transducer located in the
standpipe, which detects the pulses transmitted from the
downhole tool, and electronic circuits for detecting,
- Electrical Cable filtering, amplif@g, decoding, and displaying the
downhole data.

Sensor Package and Measurements

Six pammeters were selected for the experimental pco-
gram: natuml formation radioactivity, borehole pressure, I
— Sensor Package borehole tempmaturc, differcntinl mud resistivity, WOB
and TOB.
Unlike a directiond-snrvey MWD tool, with which
the required parameters can be measured from within the
_ Drill Collar housing of the sensor, some of the experimental sensors
required access to the exterior of the drill collnr to permit
measurements in the anmdus between the collar and
borehole wall. The sensor package incorpo~tes the six
sensors, a multiplexer, an AID conveser, and a data
control unit. The signal from the data control unit
modulates the vaIve in the transmitter, which in turn
Fig. l-Teleco downhole assembly. sends bh serial binary information, coded to a resolution
of 1 part in 1,000, to the sutiace as shown schematictdly
in Fig. 2. The range and resolution of the &ta ‘feceivcd
at the surface arc summarized in Table 1.

Formation Radioactivity. Natural gnmma radiation,

present in various litbologies5 but primarily in shale, is
mensurcd by a detector located inside the sensor hous-
ing. A reading, in counts per unit time, which approx-
imates the cfllbration of the API scale, is dkplayed as a
log.

Borehole Pressure. Borehole pressure is measured

with a miniattue presswc transducer located in the drill
collar with its diaphragm ported to the annuIar pressure.

9C0 JOURNAL
OFPETROLEUM
TECHNOLOGY
 ——

I GAMMA
I-lcos%id

——
MUD
TEMPERATURE
I tico~::ING}
1“ I I I

, !
MUD PULSE
VALVE

Fig. 2—Data transmission schematic

The signal is time avemged to eliminate the effect of the

mud pumps.

Borehcde Temperature. Temperature of the borehole NBK –

mud is measured with a transducer mounted in the wall +25
<
of the drill colkm. The active portion of ~e probe is in
~A
contact with the annular mud flow.

Differential Mud Resistivity. Differential mud

c
resistivity is measmtd with a pair of probes, orie of
which is mounted in the wall of the drill collar with its
active surface in contact with the annular mud. The :ec- Tsrmmrature
T5 Mete’s
““”
ond has its active surface in contact with the mud in the
interior of the drill c’ollar. The differefitinl.resistivity -..
measu&rnent is desigried to respond to the influx’of for-
mation fluids into the borehole.

WOB. WOB is measured by a temperature-” and

c
flexure:compensated strain-gauge bridge mounted on the
drill collar. By taking a measurement with the bit off the
bottom, the system compensates for the drill-collar
weight below the tool.
I
TOB.” The TOB measurement is identical to the WOB
measurement except that the gauges are oriented to be ~-CONNECnON
sensitive to the toriion~ shear strains in the drill collsr. c

Field Testing and Application

Demon5@ations
Fig. 3-Downhole temperature profile.
Field testing of the six-sensor tool began in July 1978.
Twelve te?m were conducted in the North Sea, Gulf of
Mexico,” and onshore in the U.S. in whicti more than
1,200 hours of drilling time were accumulated. Our main
objective was to. demonstrate that the MWD tool cnuld
perform specific tasks of value to the operator and with a
high level of reliability, Of ptiary “interest were over-
tiY 19a3 901
 :J- ~.--....—=
‘:’+ L ---------

67*G 7-

J...-_ .......... S-me Twy

6k 7 .------
. . T.-A
,.W
~—, ..
&,,

_ .
.L ~, t.-__
.’_J .-J ,OB

e
,..
,00 ~

~-&
I _@,_.%_
.-— Ekvnted
!
——- Ga@a-
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L - w-?_*_!?%_

~- WNN-N
L o
..._.’ - ——--——-+-

10 Mates
----— -d

C,C2T*
GWmLs

Fig. 4—TOB and WOB comparisons Fig. 5-Avoiding a trip.

pressure prediction for safety, WOB, TOB monitoring
for improved drilling efficiency, and formation gamma
radiation detection for casing point determination or cor-
relation logging. During the program we were able to
a$hleve continuously improved levels of reliability. Up
to 347 hours of continuous tmnsmission time was
achieved without maintenance.
In the examples of practical applications that follow,
no attempt was made to influence drilling decisions. Our
objective was to ayess the performance &d usetidness
of downhole MWD drilling and formation-evaluation
sensors in the actual drilling environment. In each case
we found that the downhole measurements provided
critical information that coidd have enhanced significant-
ly the operator’s real-time decision:rnaking capability,
leading, in trim, to impmved efficiency and safety.
Dowrrhole Temperature Profile
A borehole tempemture log (Fig. 3) exhibits several in-
teresting characteristics of dbwnhole temperature. In this
example fr6rn a well in the North Sea we note that the
log segment shown begins at a high point (about 185”F)
just after the resumption of circulation following a bit
change. This high point apppximates the actual fo~a-
tion temperature, As circulation is maintained and drill-
ing p~gresses beyond Point A, a substantial drnp in
downhoIe tempemtme occurs. R is clear t@ when cir-
culation is first INUT+ the snrface mud cools the fo:-
mation, which causes the drop. As drilling continues, the
doivnhole temperature rises until a steady sate is
reached. Beyond that point, temperature rises gradwdly
with increasing depth, following the geothermal gra-
dient. We also note the temporary drop in temperature
following each connection (Point C). This probably cor-
responds to the iemporary elimination of heat generated
by the bit while drilling.
9U2
There are four components in the heat-exchange proc-
ess: formation to mud, annular mud to drillpipe,
drillpipe to,inside mud, and heat generated consequent to
work expended by the drilling operation. A wort.hwfile
problem for future tesearch is to model this ther-
modynainic system. We believe that a successtid model
will make it possible. to interpret measured annular
tempemmre to obtain additional information about fpr-
mation ind formation-fluid characteristics.
TO? ~d WOB “Compariao~
On a well being drilled in the North Sea, a detailed com-
parison was made between the weight and torque
measutt?d downhole and at the surface (pig. 4). The hole
was vertical [2.$”)” with two near-bit stabiliiera in the
bottomhole assembly, and the surface measurements and
the downhole measurements were in consistent agree-
ment (to witMn a,few percent) with each other fOr most
of the log. However, over the segment between Points A
and B, the snrfaie and downhole data diverged. (Note
the shift in scales for the surface and downhoIe logs.
This separates I$e curves outside the segment b:twe.+n
Points A and B that .tiould othenvise overlay each other.)
Beginning at P@~,, A, the downhole weight and
downfrole”tor@e >o@ decreased for a 30-ft stretch and
returned to non?d after a connection at Point B with a
higher level ofb~th surface and downhole torque. The
sufface weight ShO”W-S in actmd increase, while there was
little chmge in the torque measured at the surfiie. The
discrepancy be@f~:n surface and downhole data suggests
that a stabilizer was hung up in a dogleg Orkeyseat Over
ttrk section of hole and was appmently alleviated when
the connicti6n” wdi’rna~e. However, in the gene~ case,
stabilizer hangup; ~f undetected, can ms~lt in ~ un-
nec+smy penalty” in ‘kt& of ‘penetration (ROP) and in
other detrimental efficts Thk example shows the vnlue
JOURNAL OF PETROLEUM TECHNOLOGY
 TaEco
(ccwts!unit time)
o m 100 IN

WIRE LINE
(API Units)
0 5 10+3 150

z I I
Wirdhe LW 6 Ray

Te!eco Lcg i% Ray -i-

Mefers

-L-
<
“kr_*.I
3

J---- .

L__----__,

50’r----- +/ \
+ + +--------: +
81 2 Hot
a, L
~ Doti.le Weim

,–—_—-_--, v -
020 ~ , Y

s--
II/m

0.,0 ~
\

m,
L mm A
Fig. 6—[dentikation of a faulty bit. Fig. 7—FormaOon gamma log

of monitoring both surface and downhole WOB/TOB how a downhole MWD gamma measurement, in real
data and of displaying both on a log inreal time even in time, can help assess bh condition and avoid m un-
straight holes. necessary trip to change bits.

Drilfing Application—Avoiding a Trip Drilling Application–Identification of a FauIty B1t

On one field test (Fig. 5), the MWD gamma log iden-
tified an alternating shale/limestone Ikhology sequence
as drilling progressed. The MWD log was later con-
firmed by a conventional wireline log.
Fig. 5 shows that the ROP decreased at about the time
when erratic torque was obsemed at the surface. The
downhole torque was lower than surface values and
relatively mcwe stable. It was also somewhat reduced
from previous readings, repeating the characteristic
value established in the earlier limestone bed, Examina-
tion of the red-time gamma log explains the low ROP as
the Iithology changed back to the slow-drilling
limestone. Thus, the identified lithology change, cou-
pled with the stable downhole torque, explained the Iow
ROP and indicated that the bit was still good. However,
the slow ROP, combined with the erratic surfice torque,
was interpreted by the driller as indicating a dull bit, and
it was pulled. The bit was in fact “green” and was
tripped back into the hole. This example demonstmtes
MAY 1983
In another field te6t (Fig. 6), the downhole torque took a
sudden jump without a corresponding jump in downbole
weight. In fact, tbe downhoIe weight decreased from
previous drilling levels and is consistent with the ROP
log. Surface torque, however, had been erratic for
several hundred feet and could not serve as a good in-
dicator of a faulty bit. The jump in downhole torque,
however, clearly indicated a problem. When the bit was
pulled, one cone was extremely loose, and a fishing
operation was barely avoided.
Efficiency/Safety Application-Identification
of a Casing Point
In the same North Sea field test discussed with Fig. 5,
and for whkh the gamma log is illustrated in Fig. 7, the
experimental tool was used to help identify the lithology
in an explomto~ well. Previous experience showed that
a thin bed of highly radioactive “hot” shale capped an
overpressured sand. The operator wanted to set casing in
903
the hot shxle.
At a point several hundred feet above the shale zone,
the experimental tool was installed, and, aa the drilling
progressed, the gamma log was plotted. The radioactivi-
ty level of the limestone above the target shafe was an-
ticipated to be less than 50 API units, while the activity
in the shale was expected to be more thm 150 API units.
This anticipated demarcation in activity W%to indicate
drilling into the shale zone. Fifty feet before the shale,
two peaks (Points A and B in F]g. 7) were observed that
correlated with an offset log, and the target shale was
therefore judged to be close.
The subsequent appearance of shale cuttings in the
dciIling mud suggested that the target shale had been
~ached, but the MWD gamma log showed that in ac-
tuality a limestone zone was being drilled. (This can also
be seen in Fig. 5, where the limestone is indicated just
before a jump in the gamma log.) The obsefved shale
cuttings at tits point were pfobably associated with the
zone at Points ‘A and B. After slow drilling in the
limestone (this is the point at which tbe driller erroneous-
ly thought the bit was worn-see discussion of Fig. 5)
the correct shale marker was finaly detected as a strong
jump in the MWD gamma log, and the string was pulled
to set casing. The postdflling wireline trace is shown in
Fig. 7 and is in good agreement with the MWD log.
In this application, the use of a real-time MWD gam-
ma log for providing a safe and accurate determination of
a casing point and for eliminating the need for one or
more intermediate wireline runs is clearly demonstrated.
Conclusions
WOB, TOE, and surface ,ROP in determining bit condi-
tion has been demonstrated. While practical applications
of the other downhole sensors require more interpre@-
tion work, their viabilhy as MWD sensors in a multisen-
sorymud-pulse system has been established.
Comidemble emphasis @ been placed on the
development of a reliability level acceptable for oilfield
use. The downbole tooI dumbifity and mggedness
achkved in the 3-year period of this experimental test
program has met the goaf.
Acknowledgments
We tiank those people at the oil companies and oilfield
service companies who have participated in the develop-
ment and have assisted in the testing of the tool,
especially C. Helm, J. Ripolone, and R. Ford.
References
1, Spionler, R.F. and Stone, F.A.: “Mud Pulse Lagging While
DrillingTelemmySystemDesign,Development, and Dcmonslrr-
fbm, 32paper pmaented at the 1978 fADC DriUi..S Technology
C.mf.twce, Houston, March 7.
2. Newton, R,, Kite, R.L., and Stone, F. A.: ‘<ACase Study Com-
Pat’iSOnof Wells Drilled With and Withow MWD Directional
Surveys on the Claymore Platform in the North Sea,” J. Pet.
Tech, (Nov. 1980) 1S67-76.
3. Tanguy, D.R. and Zoeller, W. A.: “Applications of
Meawwnems While Drillim. ,’ amer SPE [0324 m’esenkd at the
1981 SPE Amual TechDical-Co;fe’kce and Exhibition, San AII-
Io”io, Oct. 4-7.
4. Oearhm, M., Zicmer, K.A., and Knight, O. M.: “Mud Pulse
f@VD Systems Repon,>xJ. Pet. Tech. (Dec. 1981) 2301:06.
5. Pirscm, S.1.: Handbook ofWell Log Atuly$is, Prentice-Hall Inc.,
Englewaod Cliffs, NJ (1963) 26.

A multisensory MWD system has been successfully field-

S1 Metric Conversion Factors
tested in a wide variety of land xnd offshore wells, en-
compassing more than 1,200 houra of dri31ingtime dur- ft X 3.048* E–01 = m
“F (°F-32)/l.8 = o~
ing a 3-year period.
Gamma ray, mud resistivity, mud temperature, an- lbf X 4.448222 E+OO = N
mdus, WOB, and TOB measurement have been made mile x 1.609 344* E+OO = km.
downhole during drilling and transmitted to the surface psi x 6.894757 E+OO = Wa
in real time using mud-pulse telemetfy. The practi@ use .Cmvelsim
tactor
isexact m
of red-time gamma data for Iithology identification and Otigina manuscript receiwd in Socie!y of Petroleum E.$.ww dfice July 9, 1982

drilling application has been demonstrated. Moreover, Paper accepjti %2.

tor publication No.. 15, t .mvised manuscript received Feb. 7,
?sss.P.Per[SPE10056)
first presented at the 1981 SPE Annual Technrcal Co..
the value of using gamma dafa in conjunction with f’are”m and ExhiUtion held 1“ a,” Antonio, 0,!, 4-7.

9C4 JOURNAL OF PETROLEUM TECHNOLOGY