Fail-safe stage tool and down hole sensor
A fail-safe method to cement a section of casing string to a formation is provided. The method includes providing the casing string in a wellbore, the casing string comprising a stage tool, a packer, and a sensor. The packer is located vertically below the stage tool and vertically above the sensor on the casing string. The method further includes pumping cement down the casing string and up an annulus to an expected height, the expected height being a vertical distance above the sensor, and detecting a presence or absence of cement with the sensor. If the sensor detects the presence of cement, the stage tool is kept closed and the packer is kept deflated. If the sensor detects the absence of cement, the stage tool is opened and the packer is inflated.
1. A fail-safe method to cement a section of casing string to a formation comprising:
providing the casing string in a wellbore, the casing string comprising a stage tool, a packer, and a sensor, wherein the packer is located vertically below the stage tool and vertically above the sensor on the casing string;
pumping cement down the casing string and up an annulus coaxially surrounding the casing string to an expected height, the expected height being a vertical distance above the sensor;
detecting a presence or absence of cement with the sensor;
keeping the stage tool closed and packer deflated based on the sensor detecting the presence of cement; or
inflating the packer and opening the stage tool based on the sensor detecting the absence of cement.
2. The method of claim 1 wherein cement is circulated through the opened stage tool and up the annulus above the inflated packer to a predetermined height based on the sensor detecting the absence of cement, wherein the predetermined height is a vertical distance above the sensor.
3. The method of claim 2 wherein the predetermined height is the height of an outer casing string bottom in the wellbore.
4. The method of claim 2 wherein the expected height is equal to the predetermined height.
5. The method of claim 1 wherein the sensor is a pressure sensor.
6. The method of claim 1 wherein the formation further comprises a potential loss zone, the potential loss zone being a vertical distance below the pressure sensor.
7. The method of claim 1 wherein the sensor sends a signal to the surface after detecting the presence or absence of cement.
8. The method of claim 1 wherein the sensor is located between 1 and 100 feet below the stage tool.
9. The method of claim 8 wherein the sensor is located between 20 and 70 feet below the stage tool.
10. The method of claim 1 wherein the expected height is the height of an outer casing string bottom in the wellbore.
11. The method of claim 10 wherein the casing string further comprises a second stage tool and a second packer, the second stage tool and the second packer above the outer casing string bottom.