Development and evaluation of the coaxial cable casing imager: a cost‐effective solution to real‐time downhole monitoring for CO 2 sequestration wellbore integrity

CO 2 leakage is a major concern in a geological carbon sequestration projects due to adverse environmental consequences, where the main leakage risk is identified to be along existing wells through a thick, low‐permeable cap rock. To pursue robust and cost effective real‐time downhole monitoring technology for CO 2 sequestration wellbore integrity, a permanently deployed coaxial cable casing imager is developed and evaluated in laboratory in this paper. The prototype of the casing imager consists of evenly distributed coaxial cable strain sensors helically wrapped around the pipe. The system is deployed on both PVC pipe and steel pipe to test its performance in casing deformation monitoring, including axial compression, radial expansion, bending, and ovalization. The strain sensors are pre‐stressed and then helically wrapped onto the pipe with high strength epoxy. Multiple linear variable differential transformers (LVDTs) or strain gauges are used as an independent measurement of the actual pipe deformation in comparison to the casing imager measured pipe deformation. The test results demonstrated the ability of the lab‐scale casing imager prototype in real‐time casing deformation monitoring, including axial compression, radial expansion, bending, and ovalization, which would prove of great value in evaluating wellbore integrity state and providing early warnings of leakage risk that will contaminate the groundwater during CO 2 injection. The low cost and high robustness of the distributed coaxial cable sensors will greatly lower the downhole monitoring cost and increase the system longevity. © 2017 Society of Chemical Industry and John Wiley & Sons, Ltd.