During the drilling and completion of oil and gas wells, it may be necessary to engage in ancillary operations, such as monitoring the operability of equipment used during the drilling process or evaluating the production capabilities of formations intersected by the wellbore. For example, after a well or well interval has been drilled, zones of interest are often tested to determine various formation properties. These tests are performed in order to determine whether commercial exploitation of the intersected formations is viable and how to optimize production. In addition to formation testers, other tools for ancillary operations may include a measurement while drilling (MWD) or logging while drilling (LWD) tool, a reamer, a stabilizer or centralizer having moveable or extendable arms, a MWD coring tool with an extendable member, a fluid identification (ID) tool, and others. These tools for ancillary operations to drilling a borehole typically require a power source to drive the various components and devices. Many times, the power source is incorporated into the downhole tool, as opposed to being located at the surface of the well.
In some tools, batteries provide power to operate all aspects of the tool. When the batteries are depleted, they are disposed. However, batteries provide a very limited supply of energy and cannot sustain devices that draw heavily on the power source. In some simple devices, such as a mud pulse generator, a turbine is used to generate power for the mud pulser. The turbine is disposed in the drilling fluid flow bore and rotated by the drilling fluid flowing therein. The drilling fluid is constantly flowing over the turbine, providing a steady source of wear on the turbine.
New tools, such as those included with MWD or LWD systems, formation testers or fluid ID systems, for example, are increasing in size, complexity and functionality. These tools require robust and adaptable power sources. The tool may include an electric valve or electronic processor that requires a relatively small amount of power, while also including one or more hydraulically extendable devices that requires a larger burst of hydraulic power. These components of the tool may be selectively usable at different times, and may require varying levels of power during use. The tool's downhole power source must accommodate these power requirements. The tool, if it is disposed on a drill string, may be deployed in the well for long periods of time, restricting maintenance access. Preservation of moving and other active parts is critical. However, complex downhole tools are pushing the limits of current power generation assemblies, flow components and other supporting devices.
An embodiment of the apparatus includes a housing having a first flow bore and a second flow bore, the first flow bore having a drilling fluid flowing therein, a device disposed in the second flow bore to receive a fluid flow, and a diverter disposed between the first and second flow bores, the diverter having a first position preventing the drilling fluid from flowing into the second flow bore and a second position allowing a portion of the drilling fluid to flow into the second flow bore and through the device.
Another embodiment of the apparatus includes a drill collar having a first flow bore and a second flow bore, the first flow bore having a drilling fluid flowing therein, a power generation assembly disposed in the second flow bore, and a flow diverter isolating the drilling fluid from the second flow bore in a first position, wherein the flow diverter includes a variable second position directing the drilling fluid into the second flow bore at a variable flow rate.
A further embodiment of the apparatus includes a drill collar having a first flow bore with a first drilling fluid flow therein, and a second flow bore isolated from the first drilling fluid flow and having a power generation assembly disposed therein, a flow diverter adapted to direct a variable second drilling fluid flow into the second flow bore, and an MWD tool coupled to the drill collar and the power generation assembly, wherein the variable second drilling fluid flow generates a variable power supply in the power generation assembly, the variable power supply providing substantially all power to the MWD tool.
An embodiment of a method of diverting a fluid flow in a downhole tool includes flowing a fluid through a first flow bore in the downhole tool, isolating the fluid from a second flow bore in the downhole tool, and diverting a portion of the fluid to the second flow bore. A further embodiment includes varying a flow rate of the fluid to the second flow bore.
For a detailed description of exemplary embodiments of the invention, reference will now be made to the accompanying drawings in which:
In the drawings and description that follows, attempts are made to mark like parts throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Unless otherwise specified, any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Reference to up or down will be made for purposes of description with “up”, “upper”, “upwardly” or “upstream” meaning toward the surface of the well and with “down”, “lower”, “downwardly” or “downstream” meaning toward the terminal end of the well, regardless of the well bore orientation. In addition, in the discussion and claims that follow, it may be sometimes stated that certain components or elements are in fluid communication. By this it is meant that the components are constructed and interrelated such that a fluid could be communicated between them, as via a passageway, tube, or conduit. Also, the designation “MWD” or “LWD” are used to mean all generic measurement while drilling or logging while drilling apparatus and systems. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
Referring initially to
Although the various embodiments described herein primarily depict a drill string, it is consistent with the teachings herein that the MWD tool 10 and other components described herein may be conveyed in the borehole 8 via a rotary steerable drill string or a work string, for example. Other conveyances for a tool including the embodiments described herein are contemplated by the present disclosure, and the specific embodiments described herein are used for ease and clarity of description.
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Although the flow diverter assembly 102 is shown coupled to and communicating with the power generation assembly 104, it is contemplated herein that other embodiments include connecting the flow diverter assembly 102 with other components of a downhole tool. The flow diverter assembly 102 is not intended solely for a power generation apparatus, but for any combination of tool components wherein selective and variable flow diversion may be required.
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The embodiments of the flow diverter described herein are selectively usable and adjustable so as to vary the flow rate that is diverted. Certain embodiments also include a feedback and control mechanism for communicating the information necessary to determine when the flow diverter is to be used, and when the flow rate is to be varied. The flow rate to the turbine is controlled by the diverter, and the flow rate determines the speed (in rotations per minute, RPM) of the turbine and thus the power output. In one embodiment, for example, the pressure from the pumps connected to the turbine plus the speed of the turbine can be monitored as feedback for determining when the diverter need be adjusted. If multiple components of the tool are being used, and there is a power drain on the system, this feedback will reflect such circumstances and allow the diverter to be adjusted for more flow rate and thus more power from the turbine. The position of the diverter valve or rotating plate can also be monitored as feedback. If an electrical generator is coupled to the turbine, a voltage and current on the alternator may be monitored. If a pump is likewise connected to the turbine, speed and pressure can be monitored in conjunction with voltage and current. In addition to mechanical, hydraulic or electrical loads on the power generation assembly, temperature can be used as a feedback information.
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The sensors include a variety of specific sensors. For example, the sensor 316 is a position indicator for a valve or rotating plate as described herein, the sensor 318 is a sensor for detecting the speed of a turbine, the sensor 320 is a pressure sensor, the sensor 322 indicates voltage and current of the electrical generator 312, and the sensor 326 is another pressure sensor or another of a variety of sensors found in the downhole tool 314. The processor 326 may contain feedback information, such as an algorithm for a formation or fluid ID test sequence. The sensors detect certain properties and communicate them to the processor 328, which may include a baseline of the property for comparison to the measured property. For example, in one embodiment, the processor 328 includes a predetermined range of baseline speeds for a turbine in the power assembly 308. The sensor 318 measures a property of the turbine, such as the speed in RPM of the turbine, and the measured speed is compared to the stored baseline speed to determine whether the actual speed of the turbine is within the predetermined range of the baseline. If not, the flow diverter 306 is adjusted to vary the diversion path flow rate. Thus, the flow diverter is variable in response to a determination that a property is not within a predetermined range of a baseline. A similar process may be executed for measured properties of the electrical generator, such as voltage and current, or for other properties of the components previously described.
In another embodiment, the speed of the turbine in the power assembly 308 may be measured by the sensor 318, and the pressure of the pump 310 may be measured by the sensor 320. The speed and pressure measurements may be used to obtain the power output to the tool 314. Further, the feedback processor 328 may communicate with a test sequence in the tool processor 326 to anticipate an increase or decrease in the amount of power to be used by the tool 314 in the near future. For example, the processor 326 can indicate that actuation of several hydraulically powered members is to be executed in five seconds. The processor 328 will receive this feedback information, and direct the flow diverter to open, or further open, the flow diversion path to increase the fluid flow rate and thus the power output of the power assembly 308.Thus, the variable flow diverter can be actuated in anticipation of a known event. Other embodiments include other feedback information as disclosed herein.
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Other embodiments include various combinations of the components of the exemplary process 400, and still further embodiments include additional components of the embodiments described elsewhere herein. For example, in an alternative embodiment of the method 400, if it is known that a certain quantity of power is needed, the process may skip from the block 408 to the block 416 to simply provide the predetermined quantity of power. The variable diverter allows the predetermined quantity of power to be adjusted, as the embodiments described herein allow the position of the diverter to be chosen, and thus the flow rate and power chosen also. In yet another embodiment, as previously described, the feedback may include the beginning or end of a known event, and thus the method 400 may be adjusted such that the block 410 skips to the block 414, with the block 416 always being an option to end the flow diversion and power generation.
Positioning the turbine in the secondary flow bore and providing a selectively usable and variable flow diverter reduces wear on the turbine and the pump. If drilling is commencing 90 percent of the time downhole, whereas generating power for a fluid ID system or formation tester, for example, commences 10 percent of the time, the fluid flow is only affecting the turbine 10 percent of the time. Further, a variable diverter adds a control element to the speed of the turbine, whereas an all or nothing flow through the turbine provides no speed control and therefore adds complexity to the controls of the entire system. Because certain of the embodiments including a power generation assembly described herein provide a robust power supply and variability of that power supply, the embodiments are well adapted to provide all of the power needed for the complex and sizeable tools referenced herein. For example, power sources dependent on surface interaction, such as disposable batteries charged at the surface, can be eliminated.
While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 60/804,405, filed Jun. 9, 2006 and entitled “LWD Fluid Identifier.”
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US07/70902 | 6/11/2007 | WO | 00 | 12/9/2008 |
Number | Date | Country | |
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60804405 | Jun 2006 | US |