Design of High Accuracy Orientation sensor of MWD

Gong xianfeng , Yang Jing

Wang Wei

School of Mechanical Engineering, University of Science and

Technology Beijing
Beijing, China
xianfenggong@126.com

Drilling Company Jianghan Petroleum Administration of

Sinopec Directional Drilling Service Center

AbstractThis paper proposes to develop an angle measurement

system of the orientation sensor based on accelerometers and
fluxgate magnetometers. By analyzing temperature error and fix
error which affect the orientation accuracy, a new error
correcting model has been put forward. Testing results show that
the MWD orientation sensor system utilizing the suggested
compensation model is more accurate in directional drilling
operations, which has considerable values.

Qianjiang of Hubei Province, China

Tan(GTF)=

I.

INTRODUCTION

II.

Tan(MTF)=

Z-direction is the axis of the wellbore;

HY
HX

Inclination refers to the deviation of Z-direction from the

vertical direction. Computation of it is given as follows:
Tan(INC)=

G X2 + GY2
GZ

Azimuth is a clockwise deviation of the magnetic North

from the projection of the Z-direction on the horizontal plane.
Computation of it can be expressed as follows:

MWD MEASUREMENT PARAMETERS

The set of orientation sensor is primarily composed of

three-axis accelerometers, three-axis magnetometers, and some
basic processing circuits, as the Fig. 1 shows. Three
accelerometers are respectively installed in X, Y, and Z
directions of the body frame and the three fluxgate
magnetometers are installed the same way. Generally, the X,
Y, and Z directions are defined as follows:

The magnetic tool face angle (MTF) is an included angle

between X-direction and the magnetic North direction.
Computation of the MTF is presented in the following
equation:

Keywords-Orientation sensor; Temperature error; Fix error

Orientation sensor plays an important role in MeasurementWhile-Drilling (MWD) of oil drilling, but the high accuracy is
difficult to get, because it works in a harsh condition of strong
vibration and high temperature[1][2]. In this paper, an error
correcting model and algorithm of accuracy compensation have
been put forward to the sensor, and the software and hardware
is realized, thus the accuracy is good enough for MWD.

GY
GX

Tan(AZ)=

G ( H X GY + H Y G X )
H Z (G + G X2 ) H Y GZ GY H X GZ G X
2
Y

4
The accuracy of the MWD system is acceptable when
errors of the above measurement parameters are within the
following threshold values, respectively:
Inclination: 0.1q; Azimuth: 1q; Tool face: 1.5q.

X-direction is set to be perpendicular to the reference plane

of the device;
Y-direction is derived from the right-hand rule of X and Z
directions.
The outputs of accelerometers in X, Y and Z direction are
Gx, GY and Gz respectively, and that of magnetometers is Hx,
Hy and Hz.
The desired measurement parameters are the gravity tool
face angle (GTF), the magnetic tool face angle (MTF), the
inclination (INC), and the azimuth (AZ).
The gravity tool face angle (GTF) is defined to be a
clockwise deviation of the X-direction from the high side of the
wellbore, obtained when looking down straight at the wellbore.

978-1-4244-8039-5/11/$26.00 2011 IEEE

Figure 1. Definition of X, Y, Z directions about orientation sensor

ESTABLISHMENT OF THE ERROR CORRECTING MODEL

Both the fix error and the variation of operating

temperature have unavoidable effects on sensor accuracy. To
obtain a satisfying accuracy under the condition of high
vibration and broad temperature range, it is necessary to
analyze possible errors and propose solutions to them. The
measurement errors of sensors is derived from temperature
variation and fix error.
A. Temperature compensation
The mathematical model for both the accelerometer and the
fluxgate magnetometer could be expressed in the following
equation[3]:

V = SPB

5
Where V is the desired voltage outputted from the sensor; P
is the output of the sensors, among which for the
accelerometers are GX, GY and GZ (g), the gravity components
in X, Y and Z directions, respectively, while for the fluxgate
magnetometers are HX, HY and HZ (Gauss), the magnetic
components in X, Y and Z directions; B represents the zero
drift which is of the same unit as P; S is known as the scale
coefficient with a unit of V/g or V/Gauss.
What can be extracted from the above equation is that any
factor that has an effect on either S or B does affect the sensor
accuracy as well. Practically, the sensors operating temperature
disturbs S and B most, mainly in the forms of scale error and
zero drift error, respectively, and due to its huge variation,
errors caused by the operating temperature must be reduced.
1) Zero drift compensation
Zero drift is defined to be an output offset voltage of the
sensor circuit when inputting a zero-value quantity. Due to the
fact that zero drift varies with temperature, different one
corresponding to different zero drift, error will definitely exist
if applying zero drift to each calculation with the same value,
which is unacceptable in high accuracy measurements. Hence,
it bears great essentiality and significance to make clear of the
correlation between zero drift and temperature, so as to
maximally eliminate the temperatures impact on accuracy.
Based on a set of zero drift values measured at different
temperatures, a suggested method for the elimination is to
construct a best match function f(T), which could optimally
approach the true zero drift curve. Thus the zero drift value at
any specific temperature, which is a necessity for
compensating sensors during practical angles measurement,
can be yielded according to the match function f(T).
Here is an
magnetometer.

example

of

the

X-direction

fluxgate

The mathematic model based on a third-order polynomial

can be utilized to construct the desired match function f(T),
shown in expression (6).
2

f (T ) = F (0) + F (1)T + F (2)T + F (3)T

The experimental data of the fluxgate magnetometer are

listed in Table.1. According to (6), these data points are then fit
to the third-order polynomial by the Least Squares method, so

as to generate the mathematic expression of f(T), which could

yield a accurate zero drift value at any specific temperature:

f (T ) = 2.5042642e 4 + (2.0529672e 5)T

+ 1.2794722e 7T 2 + (2.33136e 10)T 3
TABLE I.

(7)

ZERO-DRIFT EXPERIMENTAL DATA OF THE X-DIRECTION

FLUXGATE MAGNETOMETER

Temperature

Zero drift
(Gauss)
Temperature

Zero drift
(Gauss)

27.10

52.16

77.41

-0.0003

-0.0006

-0.0010

-0.0013

100.82

126.84

150.00

-0.0013

-0.0012

-0.0013

-4

-2
Zero Drift Value(Gauss)

III.

x 10

Zero Drift
Best Match Function

-4
-6
-8
-10
-12
-14
0

50
100
Temperature(deg C)

150

Figure 2. Zero Drift and Its Fitting Function Curves of X-direction Fluxgate
Magnetometer

As is shown in Fig.2, the pre-compensation error of zero

drift is close to 14x10-4 Gauss within the whole operating
temperature range, while the error after applying the match
function achieves 1x10-4 Gauss, which decreases nearly one
order of magnitude than before.
2) Scale coefficient compensation
Scale coefficient refers to the ratio of sensor output to input,
which varies with temperature, and needs compensating as
well. Similar mathematic model can be applied to this scale
coefficient, and again, take the X-direction fluxgate
magnetometer for example.
TABLE II.
Temperature

Relative scale
Coefficient
Temperature

Relative scale
Coefficient

SCALE COEFFICIENT EXPERIMENTAL DATA OF X-DIRECTION

FLUXGATE MAGNETOMETER

27.10

52.16

77.41

0.9668

0.9651

0.9636

0.9625

100.82

126.84

150.00

0.9609

0.9586

0.9571

Shown as follows, the temperature experimental data of

scale coefficient are listed in Table.2; the match function
obtained through mathematic computation is represented in
expression (8); Fig.3 describes the correlation curves of scale
coefficient and match function corresponding to temperature,
respectively.

f (T ) = 9.6678063e 1 + (6.0288821e 5)T +

(8.7786514e 8)T 2 + (8.03301e 10)T 3

follows:
KXY=1.3849286e-3,
KXX=1.0000000

KXZ=

-2.2113571e-3,

After the above error analysis, the sensors integrated

models with temperature error compensation and fix error
correcting, can be described as following matrixes:
Matrix model for the three-axis accelerometers:

(8)

As is shown in Fig.3, the pre-compensation error of scale

coefficient is close to 5.3x10-2V/Gauss within the whole
operating temperature range, while the error after applying the
match function achieves 2x10-3Gauss, which also decreases
one order of magnitude than before.

G X 1
G = K
YX
Y
GZ K ZX

K XY
1
K ZY

K XZ 1 / S X (T )
0
0 V X G0 X (T )

K YZ 0
1 / SY (T )
0 VY G0Y (T )

1 0
0
1 / S Z (T ) VZ G0 Z (T )

(10)
Matrix model for the three-axis fluxgate magnetometers:
H X 1
H = K '
YX
Y
'
H Z K ZX

'
K XY

1
'
K ZY

'
'
1 / S X' (T )
K XZ
0
0 V X H 0 X (T )

'
'
'
K YZ 0
1 / S Y (T )
0 VY H 0Y (T )
1
0
0
1 / S Z' (T ) VZ' H 0 Z (T )

(11)
0.97
Relative Scale Factor

0.968

Where K and K serve as the fix error correcting

coefficients; S and S as the scale coefficients with
temperature error compensation; G0 and H0 as zero drifts
conducted by the temperature compensation.

Relative Scale Factor

Best Match Function

0.966
0.964

IV. SYSTEM HARDWARE

0.962

MSP430F149, an enhanced 16-bit MCU produced by TI

Company, is selected as the control core for the downhole
sensor. The device features a large memory space, various
interfaces, ISP capability, and a wide operating temperature
D
range of -40~125 C , all of which perfectly satisfy the
requirement of the downhole environment.

0.96
0.958
0.956
0

50
100
Temperature(deg C)

150

Figure 3. Scale Coefficient and Its Fitting Function Curves of X-direction

Fluxgate Magnetometer

B. Fix error correcting

The fix error generally consists of two types of error[4]: the
non-orthogonal error, caused by the non-orthogonal among
sensors installed on X, Y and Z coordinate axes, respectively;
the misalignment error, caused by the measurement axis of
each sensor misaligning with corresponding axis of the
coordinate system. Since neither of the two types of error
varies with the temperature, only geometric correction could
satisfy the accuracy requirement.
Geometric correction method for the fix error is based on a
mathematic model expressed by following equation:

H X = K XX H X 0 + K XY H Y 0 + K XZ H Z 0

ADS1216, a successive approximation Analog-to-Digital

converter(ADC) produced by Analog Devices, Inc., with 24-bit
resolution and 8 input channels, is selected as the A/D module
for signal acquisition. The device has a combined features of
high precision, high integration, and a wide temperature range
D
of -40~125 C . Data transmission between ADC and MCU is
realized through the serial peripheral interface (SPI), while
MCU receives and transmits orders through the serial
communication interface (SCI).
The overall system is composed of the following parts:
voltage matching module, hardware filter, signal acquisition,
MCU minimum system, power conversion, and SCI module,
etc. With the application of modular design, the system is open
to debugging and maintenance. The whole system block
diagram is shown in Fig. 4.

(9)

Where HX is the corrected X-axial magnetic component;

HX0, HY0 and HZ0 are the pre-correction magnetic components
of X, Y, and Z axes, respectively; KMN is the cross-axial acting
factor hat represents the influence imposed by N-axis on Maxis (with M or N separately standing for anyone of the X, Y
and Z axes), such as the influences Y and Z-axis fluxgate
magnetometers have on the correction of X-axis fluxgate
magnetometer. By experiments, each KMN is calibrated as

Figure 4. Block Diagram of the system

V. SYSTEM SOFTWARE
In order to assure the efficiency, readability and portability
of the procedures, the system adopts C as its programming
language. With the help of the ISP function on the
MSP430F149 chip, it becomes more convenient either to write
codes into MCU through the USB port, without getting devices
off the PCB board, or to modify the programs downloaded to
MCU in real-time just under the PC environment. The system
flow chart and error compensation flow chart are both shown in
Fig.5.

initialization

Configure error compensation

coefficients for the accelerometers,
magnetometers and temperature
sensor

Data aquisition

A/D sampling
for N times

Error
compensation

Low-pass
filtering

Angle
computation

Binary code to g or gauss

conversion
Transmit
command ?

1) Calculate compensation value for

temperature and fix error
2) Get GTF, MTF, INC and AZ

Y
Data
transmission

End

(b)

Figure 5. Main program (a) and Error Compensation program (b) flow chart

VI. TEST RESULTS AND DISCUSSIONS

When the sequential steps of hardware filtering, software
filtering and error compensations have been completed, take a
test of the newly-designed device on a standard test table. Test
results are listed in Table.3.

GTF
(degree)

TABLE IV.

Temperature

GTF
(degree)

INC
(degree)

AZ
(degree)

Gravity
(g)

25

205.4

89.5

271.2

1.0011

50

205.4

89.5

270.8

1.0012

75

205.4

89.5

270.6

1.0013

100

205.3

89.6

270.7

1.0017

110

205.3

89.6

270.8

1.0018

120

205.3

89.6

270.8

1.0017

130

205.4

89.6

270.7

1.0014

135

205.3

89.6

270.8

1.0014

150

205.4

89.6

270.8

1.0015

Fix the orientation device to a vibration table and gradually

raise the vibration intensity. Results show that the system could
still satisfy the target accuracy requirements, even imposed
with a 10g vibration.
From the above, it can be obviously concluded that the
software compensation, based on the error correcting model
proposed in this paper, has achieved acceptable effects, which
not only satisfies the requirements of practical measurements
but also accomplishes the accuracy target raised by this design.

REFERENCES

STATISTIC TESTING RESULTS OF THE MWD SYSTEM

Theoretical
AZ(degree)

HIGH TEMPERATURE TESTING RESULTS OF THE MWD SYSTEM

Save results

(a)

TABLE III.

At room temperature, the attitude measured by the

orientation device are of a 205.4etool face angle, a 89.5e
inclination, a 271.2eazimuth and a 1.001 integrated gravity.
Next put the device into the high temperature test chamber, and
carry out high temperature experiment within the range of 25
to 150 . Results are listed in Table.4. Until now we can
conclude that the system has properly met the accuracy
demands on the whole temperature range.

start

start

f 1.5 e respectively, all of which has achieved the design

requirements.

Measurement
AZ(degree)

Theoretical
INC(degree)

Measurement
INC(degree)

0
0
0.0
15
15.0
90
45
44.8
30
30.0
180
90
90.0
45
45.0
270
135
135.2
60
60.0
0
180
180.3
75
75.1
90
225
225.4
90
90.0
180
270
270.3
120
119.9
270
315
315.2
145
145.0
As is shown in Table.3, when measuring in different
attitudes at room temperature, the maximal error range for the
inclination, azimuth and tool face angle is f0.1e, f1eand

[1]

[2]

[3]

[4]

Wang Ruo. Developing history of Logging While Drilling technology,

PETROLEUM INSTRUMENTS, Vol.15, No 2, pp.35-47, 2001(In
Chinese)
Zhang Yubo and Bi Hongbo. Design of the high accuracy MWD,
Measurement Control Technology and Instruments, No 7, pp.78-80,
2007(In Chinese)
Sun Huiqing and Guo Zhiyou. Technology of Error Compensation on
Sensors, CHINESE JOURNAL OF SENSORS AND ACTUATORS, No
1, pp.90-92, 2004(In Chinese)
Paul E, Radzinski, Michael L Larronde, Jian-Qun Wu, Calculating
Directional Drilling Tool Face Offset, US7555398B22003-01-01