Formation imaging while drilling is often constrained by the hole size and mud characteristics due to the availability and limitations of logging while drilling (LWD) measurements. A unique and disruptive measurement at the bit is being introduced to image the formation as it is drilled, building on a decade-long collaboration and leveraging world-class research on drill bits, instrumentation, data interpretation, and manufacturing.

The bit-imaging system is incorporated into the drill bit, with the sensor head protruding out along with the cutting structure. The bit-imager is designed to trail the cutter element, scratching the formation just drilled and converting this interaction into force measurement that create an image with azimuthal coverage as the borehole is drilled. It is a modular, small-footprint, ruggedized sensor and associated electronics, which have been designed to collect high-frequency force and inertial data to quantify the cutter interaction with the formation. This high-density data is stored in the bit-imager’s memory and is converted into industry’s highest-resolution borehole images right at the bit with post-acquisition processing, providing the most accurate formation imaging without any impact from borehole deterioration over time.

Incorporating a formation imager at the bit is a unique feat, securely positioning it within the harsh conditions of drilling while storing optimized signals from drilling operations to create high-resolution formation images. This work presents results from lab tests, a controlled in-house drilling facility, and subsequent field tests in different geological settings. The lab experiments on rock slabs identified layering and fractures distinctly. Geological feature recognition was also validated through a controlled drilling environment simulation in a technology center, providing confidence in its success under downhole conditions. Results illustrate that the at-bit imager can achieve higher fidelity and resolution than industry-standard wireline imagers and LWD imagers, while capturing subtle details of textural variations in addition to regular bedding and sedimentary features. Subsequent field tests provided excellent validation using offset well and field data for sedimentary features.

Revolutionary engineered design and rigorous lab experiments, followed by multiple field tests, resulted in the introduction of a disruptive technology providing the first-ever formation imaging capability right at the drill bit.