This application is the U.S. national stage application of International Application PCT/N02019/050036, filed Feb. 13, 2019, which international application was published on Aug. 22, 2019, as International Publication WO 2019/160426 in the English language. The International Application claims priority of Norwegian Patent Application No. 20180237, filed Feb. 14, 2018. The international application and Norwegian application are both incorporated herein by reference, in entirety.
The invention relates to a downhole measurement tool assembly for measuring and storing at least one quantity in a wellbore. The invention further relates to a downhole measurement tool system comprising such downhole measurement tool assembly. More generally, the invention relates to a wireless communication interface between a downhole measurement tool assembly and a surface system such as a computer or a similar device that is able to send/receive/store data as well as send control commands back to the tool wirelessly, when the downhole tool assembly is at surface out of the wellbore.
Downhole measurement tools are used in several industries, such as, but not limited to, the hydrocarbon exploration and production (E&P) industry. At present there is a plethora of downhole measurement tools that are applied in a wellbore, examples are, but not limited to, Measurement-While-Drilling (MWD) tools, Logging-While-Drilling (LWD) tools, Directional Drilling tools, wireline, and the like. One or more downhole measurement tools, connected together, forms a downhole measurement tool assembly. Such downhole measurement tool assemblies are extensively used to efficiently drill (and steer) the well in the desired direction and to obtain measurements while drilling to evaluate and interpret where to place the wellbore in order to reach the desired target and/or optimize for production of oil and gas.
Many of the Downhole Measurement tools, such as MWD and LWD tools, store all or parts of the measurements made whilst downhole in a memory locally to the downhole tool and/or in a central memory storage accessible in another downhole measurement tool as part of the downhole measurement tool assembly, which typically is a part of the bottom hole assembly. The measurements (and other data such as diagnostics) residing in the memory is typically retrieved when the downhole measurement tool assembly is pulled to surface. The operation of pulling a bottom hole assembly to surface, and subsequently reading and lying down or setting back the bottom hole assembly in the setback is considered in the critical path, and for efficiency and cost reasons seek to minimize the time taken for such operations. The time taken to read a downhole measurement tool assembly memory (dump memory) and/or power down (control) a downhole measurement tool assembly is therefore important to improve efficiency by making decisions earlier, to reduce cost and to reduce (and/or eliminate) health-safety and environmental hazards.
Surface communication with a downhole measurement tool assembly is typically performed with cables, where an operator removes the necessary protection of the downhole tool, such as plugs, in order to physically connect to the downhole tool, and start the communication. This is typically performed at the drill floor, and represents several hazards, such as dropped objects and ignition.
The wellbore can present extremely harsh (hazardous) environment where high temperatures, high pressures and severe mechanical loading is encountered. For several reasons, such as high cost of re-performance and potential catastrophic consequences of wellbore/drill string integrity issues, the downhole measurement tools that are subjected to this environment must perform flawlessly, therefore downhole measurement tool design integrity is of paramount matters.
In many cases, several downhole measurement tools are required, and typically for practical reasons shipped to the drilling site in sections. The sections are made-up and built in the derrick to form an assembly called a downhole measurement tool assembly.
A key element to this background is the preparation and configuration of the downhole measurement tool(s) prior to the operation of running in with the bottom hole assembly. The operation of configuring (communication to) the downhole measurement tool assembly is typically performed while the downhole measurement tools are hanging in the derrick and/or in the drill floor slips for several reasons, such as the downhole measurement tools may require to be electrically connected to a power and communication bus, requiring an active connection to all (or several) downhole measurement tools included in the downhole measurement tool assembly and/or for calibration and confidence testing purposes. This means that the operation takes place at the drill floor which is very often classified as “red zone” and work permits are required for operating equipment which is not intrinsically safe. The communication is traditionally carried out using a surface system, by physically connecting a cable (including connector) to the downhole tool. The surface system typically also consists of a computer and may be situated at the drill floor or otherwise connected via a cable to other locations at the rig. The connector residing in the downhole measurement tool is often behind a plug and/or hatch like solution, to protect the connector from the harsh environment whilst downhole. As there are many hazards at the drill floor, the operation of connecting and communicating with a downhole tool is often performed sequentially as opposed to simultaneous with other operations on the rig, meaning that most, if not all, other operations at the drill floor stop and wait until the operation of communicating with the downhole measurement tool is finished and complete. This said operation of physically connecting and communicating with the downhole measurement tool at the drill floor not only puts the operator in danger but exposes the downhole measurement tool vital electronics to the drill floor environment which is often full of debris and drilling mud.
In post drilling activities when the tool has been retrieved from the wellbore, there are two means by which the data can be accessed and read; the tool can either remain coupled to the remaining drill string or alternatively it will have to be disconnected and removed from the drill string. The data is then extracted the same way as when the tool has been initially set up by means of a physical, hardwired connection to the computer or a similar device.
In the case of accessing the data whilst the tool is still part of the drill string, the operator must enter the hazardous “red zone”, remove a sidewall readout plug and connect a plug and/or cable into the tool to retrieve the data, as well as functionally shut-down the tool. As mentioned earlier, this not only puts the operator in great danger but also exposes the vulnerable electrical connections to the drill floor environment and the rig will have to wait until this is finished. Additionally, whilst the tool is still connected to the remaining drill string there may be a time factor involved as there will be a limited amount of time given to establish communication and retrieve the data, since the geologist and drilling engineers are highly interested in getting access to the data.
If the downhole measurement tool assembly can be removed it can be relocated to a safe area where the operator can safely carry out the task of making an electrical connection and extracting the data. This is generally close to the wellsite or in some instances it can be a distance away where the tool will require transportation before any connections can be made. The data extraction processes described can therefore be time consuming but more critically detrimental to the data transfer where there are risks of seized connector caps, blocked electrical connection points, poor contact due to dirt ingress, broken connector contacts, etc. These risks can pose a huge effect on the overall project resulting in compromising safety, budget and time factors which are highly prized during oil exploration.
For the problems described above some technologies have been presented.
WO2008/005193A2 discloses an example of a method and system for wireless communication.
U.S. Pat. No. 4,736,204 discloses a resistivity downhole measurement tool comprising of external sensors for measuring the formation. This tool applies the same sensors as wireless antennas during data transfer operations. This method of data transfer utilizing the downhole sensor, although it being wireless, requires the transmitter/receiver to be in close proximity of the external sensors/antennas of the measurement tool. This can be disadvantageous in instances where the measurement tool is located in a hazardous location especially when it is still part of the drilling string whereby an operator would be required to place a transmitter/receiver to make the necessary data transfer.
In view of the above described problems there is a further need to develop wireless transmission solution for downhole tools, in particular downhole measurement tool assemblies, when the downhole tool assembly is at the surface out of the wellbore.
The invention has for its object to remedy or to reduce at least one of the drawbacks of the prior art, or at least to provide a useful alternative to prior art.
The object is achieved through features, which are specified in the description below and in the claims that follow.
The invention is defined by the independent patent claims. The dependent claims define advantageous embodiments of the invention.
In a first aspect the invention relates to a downhole measurement tool assembly for measuring at least one quantity in a wellbore. The downhole measurement tool assembly comprises:
The effects of the features of the downhole measurement tool assembly in accordance with the invention are as follows. First of all, the downhole measurement tool assembly is configured for measuring at least one quantity in the wellbore and for storing values of said at least one quantity to obtain stored measurement data. In addition, the downhole measurement tool assembly is configured for wirelessly communicating said information (stored measurement data) to an external read-out system through an antenna system. It is important to note that this read-out only occurs at the surface out of the wellbore. The downhole measurement tool assembly is not configured for real-time communication of measurement data. While residing downhole the downhole measurement tool is configured for only measuring and storing measurement data and not for communicating said data. The downhole measurement tool is only communicating said stores measurement data with the externally located read-out system while residing at the surface out of the wellbore. The antenna on the downhole measurement tool assembly itself is dedicated to the required communication of the stored measurement data between the downhole measurement tool assembly and the external read-out system while both the external read-out system and the downhole measurement tool assembly reside at the surface out of the wellbore. In addition, this antenna is externally provided, that is it is provided at the exterior of the pressure housing without the presence of a pressure sealing window. That the antenna is provided at the exterior side of the pressure housing does not exclude the possibility that it could be located in a trench provided at the exterior of the pressure housing. The pressure connector can either be a separate part or it can be integrated with the antenna. As long as the antenna is subject to the external pressure of the wellbore (when residing in the wellbore) it falls within the scope of the claims. The pressure connector allows the antenna, that is exposed to the external pressure, to be connected to the transceiver that is located within the pressure housing and exposed to lower pressures.
The invention, in contrast with WO2008/005193A2, avoids the described pressure seal window in WO2008/005193A2 and the window's potential negative effect on the mechanical strength of the pressure retaining components. In addition, locating the antenna on the exterior of the pressure housing additionally improves transmission of the wireless signal, thereby reducing the chance of data corruption during a memory dump and potential control issues of the downhole measurement tool assembly.
In order to facilitate understanding of the invention, one or more expressions are further defined hereinafter.
Wherever the wording “drill floor” is used, this is interpreted to be the heart of any drilling rig (such as an oil rig, but the drill floor may also be on a boat or other floating vessel), i.e. the area where the drill string begins its trip into the earth. It is traditionally where joints of pipe are assembled, as well as the downhole measurement tool assembly, bottom hole assembly including drilling bit, and various other tool assemblies. This is the primary work location for roughnecks and the driller. The drill floor is located directly under the derrick or drill tower. The floor is typically a relatively small work area in which the rig crew conducts operations, usually adding or removing drill pipe to or from the drill string. The drill floor is the most dangerous location on the rig because heavy iron is moved around there.
In a first main embodiment of the downhole measurement tool assembly in accordance with the invention, the antenna is provided within a recess in the pressure housing. The advantage of this embodiment is that the antenna is more protected against wear caused by cuttings, mud, oil, water and other substances that are present in the wellbore.
In a further embodiment of the downhole measurement tool assembly in accordance with the invention the antenna is encapsulated in an encapsulation material within the recess. The encapsulation material helps in further protecting the antenna against wear. The encapsulation material may be selected from a group consisting of: epoxy, fiberglass, polymeric, elastomeric.
In a second main embodiment of the downhole measurement tool assembly in accordance with the invention, the antenna is provided on an external surface of the pressure housing. The advantage of this embodiment is that the integrity of the pressure housing is not compromised.
In a further embodiment of the downhole measurement tool assembly in accordance with the invention the antenna has been mounted to the pressure housing by techniques selected from the group consisting of: mechanical fastening, chemical bonding, pressure bonding, and interference fastening.
In an embodiment of the downhole measurement tool assembly in accordance with the invention the antenna is covered by a cover layer. The cover layer helps in further protecting the antenna against wear. The material for cover layer may be selected from a group consisting of: epoxy, fiberglass, polymeric, elastomeric.
In an embodiment of the downhole measurement tool assembly in accordance with the invention the downhole measurement tool assembly further comprises at least one more antenna that is dedicated to and configured for allowing communication of measurement data between the downhole measurement tool assembly and the external read-out system while both the external read-out system and the downhole measurement tool assembly reside at the surface out of the wellbore. Using multiple antennas for communication allows for communicating information in parallel OR it may be used to make a more sophisticated antenna system, wherein said antennas are configured to cooperate.
In a first variant of the last embodiment of the downhole measurement tool assembly in accordance with the invention, said antennas are distributed around the circumference of the downhole measurement tool assembly.
In a second variant of said embodiment of the downhole measurement tool assembly in accordance with the invention, said antennas are distributed over the length of the downhole measurement tool assembly.
The first and second variant may also be combined, particularly where there are three or more antennas on the downhole measurement tool assembly.
In a second aspect the invention relates to a downhole measurement tool system comprising the downhole measurement tool assembly in accordance with the invention and an external read-out system, wherein the external read-out system comprises a further antenna and a further transceiver coupled to the further antenna for controlling the communication via the further antenna. As is true for every (wireless) communication system there is both a sender and a receiver side, wherein the roles of these sides even may change back and forth. The downhole measurement tool system in accordance with the second aspect expands the invention from the downhole measurement tool assembly to the actual external read-out system that is used to read-out said downhole measurement tool assembly from a distance while residing at the surface out of the wellbore.
In a first main embodiment of the downhole measurement tool system in accordance with the invention the external read-out system is further coupled to other surface equipment. This coupling may be wireless or wired. In a second main embodiment of the downhole measurement tool system in accordance with the invention the external read-out system forms part of surface equipment. In both main embodiments the surface equipment may be selected from the group consisting of: computer, laptop, mobile device and tablet.
In the following is described an example of a preferred embodiment illustrated in the accompanying drawings, wherein:
Various illustrative embodiments of the present subject matter are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The present subject matter will now be described with reference to the attached figures. Various systems, structures and devices are schematically depicted in the drawings for purposes of explanation only and so as to not obscure the present disclosure with details that are well known to those skilled in the art. Nevertheless, the attached drawings are included to describe and explain illustrative examples of the present disclosure. The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e. a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e. a meaning other than that understood by skilled artisans, such a special definition will be expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase.
The purpose of the invention is to achieve a wireless communication interface between a downhole measurement tool assembly and a surface system such as a computer or a similar device that is able to send/receive/store data as well as send control commands back to the downhole measurement tool assembly wirelessly. This new technology offers efficient means of wireless data transfer with an additional advantage of ensuring that the mechanical integrity of the pressure housing is not compromised. This innovative means of wireless communication can be applied to a variety of downhole measurement tools from through-bore drill string mounted items to fully enclosed pressure housings mounted within the bore of the drill string.
The solution will reduce costs and reduce risk in that it will avoid operators to have to connect to the downhole measurement tool assembly at drill floor with associated HSE risk and personnel cost. It will also reduce costs by eliminating the rig idle time, while operators establish physical connection with the downhole measurement tool assembly and communicates with the downhole measurement tool assembly over the wire.
The downhole measurement tool assembly 10 in
The downhole measurement tool assembly 10 further comprises an antenna 13 that is provided at the external side 11s of the pressure housing 11. In this embodiment the antenna 13 is provided in a recess 11t (
The transceiver 15 is located in the pressure housing 11 and is coupled to the antenna 13 for controlling the communication via the antenna 13. The transceiver 15 is further coupled to a memory 16, wherein measured values of the at least one quantity are stored, also referred to as “measurement data”. The memory 16 can be in the same pressure housing 11 as the transceiver 15 or in another pressure housing placed in the downhole measurement tool assembly 10, as long as the memory 16 can communicate and transfer signals to the transceiver 15. Additional electronics 17 are provided and coupled to the transceiver 15 and the memory 16 for controlling and steering the communication of measurement data. Furthermore, the memory 16 is also coupled to power lines 18 and bus lines (communication buses) 19 that are present in the downhole measurement tool assembly 10.
So far, only the communication circuitry at the side the downhole measurement tool assembly 10 were discussed. On the other side of the communication system there is an external read-out system 20, which comprises a further antenna 21 coupled to a further (external) transceiver 22 as illustrated in
As
In a variation on the embodiments of
Potting/encapsulating material 12 as shown on
The external transmission devices represented in
The system comprising of the elements depicted in
As previously mentioned in the embodiment of this disclosure the summation of external components antenna 21 and external transceiver 22 can be realised as a computer capable of being receptive to a wireless signal emitted by the antenna 13, where the data can be stored and/or where control signals can be transmitted back to the downhole measurement tool assembly 10 wirelessly while both the external read-out system 20 and the downhole measurement tool assembly 10 reside at the surface out of the wellbore. It is also possible to treat the summation of the external antenna 21 and the external transceiver 22 as a standalone passive device 20 which relays the signal to an external surface device 30 such as a computer, the communication to the external surface device 30 can be but is not limited to wireless communication and/or wired connection. A plurality of external surface devices 30, antennas 21 and external transceivers 22 can exist which in turn can create a network and/or extend the line of communication.
An important purpose of the invention is to establish wireless tool communication while at the same time ensuring that the mechanical components, in particular the pressure housing 11, remains structurally intact, thereby not permitting the external environment of the downhole measurement tool assembly 10 to penetrate the intentionally sealed internal components. In contrast with the prior art solutions, this is resolved by placing the antenna 13, which is capable of transmitting a wireless signal, on the outer surface(s) of the pressure housing 11. This is possible because of the use of the pressure connector 14, which acts as a signal interface between the antenna 13 and the internal transceiver 15 as well as isolating the internal environment from the external pressure and media. With the antenna 13 being located on the exterior surface of the pressure housing 11 the wireless signal being emitted/received will undergo minimal attenuation thereby improving the signal strength and reducing the probability of transmitting corrupted data.
The fundamental principle of operation for the current invention is that data and commands can be wirelessly exchanged between the downhole measurement tool assembly 10, the perimeter of which is indicated by the dotted line in
Referring to
The data which is collected by the downhole measurement tool assembly 10 is communicated through the downhole measurement tool assembly 10 by means of a bus-type network 19 and distributed to the necessary components, this will include raw data taken from various sensors and transducers and command prompts allowing forms of control within the downhole measurement tool assembly 10. The power will be supplied internally by means of internal battery pack (not shown). Communication occurs when data and/or command prompts are stored within the memory 16 and communicated with the internal transceiver 15, which generates a wireless signal that is carried through the pressure connector 14 and emitted by means of an antenna 13 mounted to the extremity of the pressure housing 11. The further antenna 21 coupled to an external transmitter device 22 can be mounted at a distance away from, as well as being located in close proximity of, the antenna 13 and be receptive of the wireless signal emitted by antenna 13.
The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. For example, the method steps set forth above may be performed in a different order. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the invention. Accordingly, the protection sought herein is as set forth in the claims below.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. In the device claims enumerating several means, several of these means may be embodied by one and the same item of hardware.
Number | Date | Country | Kind |
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20180237 | Feb 2018 | NO | national |
Filing Document | Filing Date | Country | Kind |
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PCT/NO2019/050036 | 2/13/2019 | WO |
Publishing Document | Publishing Date | Country | Kind |
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WO2019/160426 | 8/22/2019 | WO | A |
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Number | Date | Country | |
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20210071520 A1 | Mar 2021 | US |