This disclosure relates to logging a well and, more particularly, logging a well downhole of a hydrocarbon production unit positioned in a wellbore, e.g., a horizontal well or a deviated well.
Gaining access within a wellbore below hydrocarbon production unit, such as a pump or production inlet, may be desirable for a field asset operator to determine, for example, reservoir characteristics. Conventionally, bypass equipment, such as a “Y-tool,” allows the capability of accessing a reservoir for logging purposes when a pump (for example, an electrical submersible pump (ESP)) is installed. Installation of Y-tools are typically restricted to a casing size of a completion of the wellbore. To log a well with a Y-Tool installed, a logging crew needs to be mobilized for the operation. Access to the well is via the by-pass leg of the Y-Tool. Mobilizing crews to perform logging operations can take some time to schedule the job depending on, for example, an availability of the logging crew. This incurs non-productive time for the field asset operator to acquire needed reservoir data for production planning. Furthermore, mobilizing a logging crew can be expensive, and even more so when there may be limited availability of the crew. Such high costs translate to a non-economical bottom line for a well operator.
This disclosure describes a downhole tool for logging a well (also called a wellbore). In some aspects, the downhole tool includes a production sub-assembly and a logging sub-assembly coupled to a downhole end of the production sub-assembly. The production sub-assembly operates to produce a wellbore fluid to the surface (for example, by artificial lift or natural circulation, or both) in a production operation. The logging sub-assembly operates to log a portion of the wellbore downhole of the downhole tool in a logging operation. In some aspects, the downhole tool may simultaneously complete the production operation and the logging operation.
In an example implementation, a downhole tool includes a production unit configured to fluidly couple to a production tubing positioned in a wellbore that is formed from a terranean surface to a subterranean formation. The production unit includes an inlet configured to fluidly couple to the wellbore to receive a production fluid. The tool further includes a logging unit coupled to a downhole end of the production unit. The logging unit includes a cable spooler configured to move a cable from the cable spooler through the wellbore downhole of the production unit, the cable including one or more logging sensors, and a cable motor configured to operate the cable spooler to move the cable through the wellbore downhole of the production unit.
In an aspect combinable with the example implementation, the production unit includes a downhole pump assembly.
In another aspect combinable with any of the previous aspects, the downhole pump assembly includes a pump motor, a production fluid pump coupled to the pump motor, and a pump intake that includes the inlet.
In another aspect combinable with any of the previous aspects, the downhole pump assembly further includes a monitoring sub-assembly coupled to a downhole end of the pump motor, and a motor protector coupled between the pump motor and the intake.
In another aspect combinable with any of the previous aspects, the logging unit is coupled to the monitoring sub-assembly.
In another aspect combinable with any of the previous aspects, the downhole pump assembly includes an electrical submersible pump (ESP).
In another aspect combinable with any of the previous aspects, the cable includes a fiber optic cable.
In another aspect combinable with any of the previous aspects, the logging unit further includes a weight attached to a downhole end of the cable.
In another aspect combinable with any of the previous aspects, the one or more logging sensors is configured to record at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property of the subterranean formation.
In another aspect combinable with any of the previous aspects, the logging unit is coupled to the inlet of the production unit.
In another aspect combinable with any of the previous aspects, the cable includes a fiber optic cable.
In another aspect combinable with any of the previous aspects, the logging unit further includes a weight attached to a downhole end of the cable.
In another aspect combinable with any of the previous aspects, the one or more logging sensors is configured to record at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property of the subterranean formation.
In another example implementation, a method includes running a downhole tool into a wellbore on a production tubular. The wellbore is formed from a terranean surface to a subterranean formation. The downhole tool includes a production unit and a logging unit coupled to a downhole end of the production unit. The method further includes positioning the downhole tool in the wellbore adjacent the subterranean formation; unspooling a cable from the logging unit in a direction downhole of the downhole tool; logging the wellbore with the unspooled cable; and during logging of the wellbore, producing a wellbore fluid from the wellbore through an inlet of the production unit and into the production tubular.
In an aspect combinable with the example implementation, producing the wellbore fluid from the wellbore includes pumping the wellbore fluid from the wellbore with a downhole pump assembly of the production unit.
Another aspect combinable with any of the previous aspects further includes, during production of the wellbore fluid, measuring at least one parameter associated with the downhole pump assembly; and transmitting the measured at least one parameter to the terranean surface.
In another aspect combinable with any of the previous aspects, pumping the wellbore fluid from the wellbore with the downhole pump assembly of the production unit includes pumping the wellbore fluid from the wellbore with an electrical submersible pump (ESP) that includes an intake that includes the inlet.
In another aspect combinable with any of the previous aspects, logging the wellbore includes measuring one or more parameters of the subterranean formation with the cable that includes a fiber optic cable.
In another aspect combinable with any of the previous aspects, the one or more measured parameters of the subterranean formation includes at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property.
In another aspect combinable with any of the previous aspects, producing the wellbore fluid from the wellbore includes receiving the wellbore fluid into the inlet of the production unit based at least in part on a pressure difference between the subterranean formation and the production string.
In another aspect combinable with any of the previous aspects, logging the wellbore includes measuring one or more parameters of the subterranean formation with the cable that includes a fiber optic cable.
In another aspect combinable with any of the previous aspects, the one or more measured parameters of the subterranean formation includes at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property.
In another example implementation, a downhole tool system includes an electrical submersible pump (ESP) assembly configured to couple to a downhole conveyance that includes a production fluid flow path for a production fluid from a subterranean formation; and a logging sub-assembly directly coupled to a downhole end of the ESP assembly and including a length of logging cable spoolable off a cable spool of the logging sub-assembly within a wellbore.
In an aspect combinable with the example implementation, the ESP assembly includes a pump that includes an intake configured to fluidly couple to an annulus of the wellbore to receive the production fluid from the subterranean formation; and a pump motor coupled to the intake at a downhole end of the pump.
In another aspect combinable with any of the previous aspects, the logging sub-assembly further includes a spooler motor coupled to the cable spool and operable to spool the logging cable from and onto the cable spool; and a weight coupled to first portion of the logging cable opposite a second portion of the logging cable that is coupled to the cable spool.
Another aspect combinable with any of the previous aspects further includes at least one power cable electrically coupled to at least one of the pump motor or the spooler motor and configured to transfer electric current to the at least one of the pump motor or the spooler motor from a terranean surface.
In another aspect combinable with any of the previous aspects, the logging cable includes at least one fiber optic cable that includes at least one logging sensor.
In another aspect combinable with any of the previous aspects, the at least one logging sensor is configured to measure at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property of the subterranean formation.
Implementations of a downhole tool according to the present disclosure may include one or more of the following features. For example, the downhole tool may enable or help enable logging access below a downhole pump, such as an electric submersible pump. As another example, the downhole tool may save service crew costs associated with logging a well if a conventional Y-tool (by-pass) tool was installed. As yet a further example, the downhole tool may save time required to schedule and mobilize a logging crew and unit when logging of a wellbore under (or directly before or after) production is desired. As another example, the downhole tool may enable independent control and operation of a logging unit separate from a pumping unit within a single tool or tool assembly. As a further example, the downhole tool may be integrated seamlessly into existing downhole pump (for example, ESP) completions.
Certain aspects of the subject matter described here can be implemented as a downhole tool. The tool includes a production unit and a logging unit. The production unit is configured to fluidly couple to a production tubing positioned in a wellbore that is formed from a terranean surface to a subterranean formation and that includes a vertical portion and a horizontal portion. The production unit can be positioned in the vertical portion of the wellbore. The production unit includes an inlet that can fluidly couple to the wellbore to receive a production fluid. The logging unit is coupled to a downhole end of the production unit. The logging unit includes a cable spooler, a cable motor and a tractor. The cable spooler can move a cable from the cable spooler through the wellbore downhole of the production unit. The cable includes one or more logging sensors. The cable motor can operate the cable spooler to move the cable through the wellbore downhole of the production unit. The tractor is attached to the cable spooler. The tractor can detach from the cable spooler to travel from the vertical portion of the wellbore to the horizontal portion of the wellbore, and responsively to carry the cable from the cable spooler into the horizontal portion of the wellbore.
An aspect combinable with any other aspect includes the following features. The tractor includes a tractor body, multiple extendable and retractable arms, and multiple rotatable wheels. Each arm is attached to the tractor body. Each wheel is attached to a respective arm of the multiple arms.
An aspect combinable with any other aspect includes the following features. The tractor can be actuated by hydraulic or electrical power. The multiple arms can extend or retract in response to the tractor being actuated.
An aspect combinable with any other aspect includes the following features. The multiple rotatable wheels can rotate in response to the tractor being actuated.
An aspect combinable with any other aspect includes the following features. The tractor can travel within the horizontal portion in response to instructions received from the terranean surface.
An aspect combinable with any other aspect includes the following features. The cable includes a fiber optic cable.
An aspect combinable with any other aspect includes the following features. The logging unit includes a weight attached to a downhole end of the cable.
An aspect combinable with any other aspect includes the following features. The one or more logging sensors can record at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property of the subterranean formation.
Certain aspects of the subject matter described here can be implemented as a method. A downhole tool is run into a wellbore on a production tubular. The wellbore is formed from a terranean surface to a subterranean formation and includes a vertical portion and a horizontal portion. The downhole tool includes a production unit and a logging unit coupled to a downhole end of the production unit. The downhole tool is positioned in the wellbore adjacent the subterranean formation. A cable is unspooled from the logging unit in a direction downhole of the downhole tool. The cable travels through the vertical portion. The cable is carried through the horizontal portion to a downhole location within the horizontal portion. The horizontal portion of the wellbore is logged with the unspooled cable. After logging the wellbore, the cable is carried through the horizontal portion from the downhole location in an uphole direction towards the logging unit. The cable is spooled in the uphole direction towards the logging unit.
An aspect combinable with any other aspect includes the following features. To carry the cable through the horizontal portion to the downhole location within the horizontal portion, an end of the cable is attached to a tractor configured to detach from the logging unit and to travel from the vertical portion of the wellbore to the horizontal portion of the wellbore. The tractor, to which the end of the cable is attached, is detached from the logging unit. The tractor travels through the vertical portion under gravity until the tractor reaches an entrance to the horizontal portion. After the tractor reaches the entrance to the horizontal portion, the tractor is controlled to travel through the horizontal portion while the tractor is attached to the end of the cable.
An aspect combinable with any other aspect includes the following features. The tractor includes a tractor body, multiple extendable and retractable arms and multiple rotatable wheels. Each arm is attached to the tractor body. Each wheel is attached to a respective arm of the multiple arms. To control the tractor to travel through the horizontal portion, after the tractor reaches the entrance to the horizontal portion, the multiple arms are extended until each wheel on each arm contacts an inner surface of the horizontal portion. Then, each wheel is rotated.
An aspect combinable with any other aspect includes the following features. After the tractor reaches the entrance to the horizontal portion, the multiple arms are actuated by hydraulic or electrical power.
An aspect combinable with any other aspect includes the following features. The one or more measured parameters of the subterranean formation include at least one of a resistivity, a conductivity, a pressure, a temperature, or a sonic property.
An aspect combinable with any other aspect includes the following features. To produce the wellbore fluid from the wellbore, the wellbore fluid is received into the inlet of the production unit based at least in part on a pressure difference between the subterranean formation and the production string.
Certain aspects of the subject matter described here can be implemented as a downhole tool system. The system includes a production unit and a logging unit. The production unit can fluidly couple to a production tubing positioned in a wellbore that is formed from a terranean surface to a subterranean formation and that includes a vertical portion and a horizontal portion. The production unit can be positioned in the vertical portion of the wellbore. The production unit includes an inlet that can fluidly couple to the wellbore to receive a production fluid. The logging unit is coupled to a downhole end of the production unit. The logging unit includes a receptacle, a tractor and multiple sensors. The receptacle can couple to a downhole end of the production unit. The tractor is attached to the receptacle and can detach from the receptacle to travel from the vertical portion of the wellbore to the horizontal portion of the wellbore. The multiple sensors are attached to the tractor and can log wellbore data in the horizontal portion of the wellbore. The tractor can transmit the logged wellbore data to the terranean surface.
The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
As shown, the wellbore system 10 accesses a subterranean formation 40 and provides access to the production fluid 50 (for example, hydrocarbons or otherwise) located in such subterranean formation 40. In an example implementation of system 10, the system 10 may be used for a production operation in which a production fluid 50 (for example, oil, gas, mixed oil and gas, water) may be produced from the subterranean formation 40 within the wellbore tubular 17 (for example, as a production tubing).
A drilling assembly (not shown) may be used to form the wellbore 20 extending from the terranean surface 12 and through one or more geological formations in the Earth. One or more subterranean formations, such as subterranean zone 40, are located under the terranean surface 12. As will be explained in more detail below, one or more wellbore casings, such as a surface casing 30 and intermediate casing 35, may be installed in at least a portion of the wellbore 20. In some embodiments, a drilling assembly used to form the wellbore 20 may be deployed on a body of water rather than the terranean surface 12. For instance, in some embodiments, the terranean surface 12 may be submerged under an ocean, gulf, sea, or any other body of water under which hydrocarbon-bearing formations may be found. In short, reference to the terranean surface 12 includes both land and underwater surfaces and contemplates forming and developing one or more wellbore systems 10 from either or both locations.
In some embodiments of the wellbore system 10, the wellbore 20 may be cased with one or more casings. As illustrated, the wellbore 20 includes a conductor casing 25, which extends from the terranean surface 12 shortly into the Earth. A portion of the wellbore 20 enclosed by the conductor casing 25 may be a large diameter borehole.
Downhole of the conductor casing 25 may be the surface casing 30. The surface casing 30 may enclose a slightly smaller borehole and protect the wellbore 20 from intrusion of, for example, freshwater aquifers located near the terranean surface 12. The wellbore 20 may then extend vertically downward. This portion of the wellbore 20 may be enclosed by the intermediate casing 35. In some aspects, the intermediate casing 35 may be a production casing 35 in which one or more perforations (not shown in
As shown in
In this example, the downhole tool 200 is positioned just uphole of perforations 65 that have been formed (for instance, shot) in the production casing 35. As shown in this example, downhole tool 200 is positioned downhole of a wellbore seal 55 (for example, a packer, bridge plug, or other wellbore seal) within the annulus 60 of the wellbore 20. The production tubing 17 extends through the wellbore seal 55 and to the surface. The wellbore seal 55, therefore, creates a production zone of the wellbore 20 downhole of the seal 55, and wellbore fluids (such as production fluid 50) are not fluidly communicated from the production zone uphole of the wellbore seal 55.
In this example implementation of the downhole tool 200, the production unit 202 includes a pump 206. In some aspects, the pump 206 is an electrical submersible pump (ESP) (ESP 206). Alternatively, the pump 206 may be a progressive cavity pump, centrifugal pump, or other downhole artificial lift device that obstructs access to the subterranean formation 40 for logging purposes. The pump 206, in this example, is used to lift wellbore fluids (for example, production fluid 50) to the terranean surface 12, or if at or near the terranean surface 12, transfers fluid from one location to another.
Directly downhole of the pump 206 in the production unit 202 is an intake 208. The intake 208 includes one or more apertures (for example, adjustable to open and close or fixed in an open position) that fluidly couples the pump 206 with the annulus 60 of the wellbore 20. The pump 206, in fluid communication with the annulus 60 through the intake 208, may then receive a wellbore fluid therein to lift the fluid to the terranean surface 12 during operation.
In some aspects, the pump 206 includes one or more stages, each of which comprises an impeller and a diffuser. An impeller, which is rotating, adds energy to the wellbore fluid received into the intake 208 to provide head. The diffuser, which is stationary, converts the kinetic energy of the wellbore fluid from the impeller into head. In some aspects, the pump stages are stacked in series to form a multi-stage system that is contained within the pump 206. The sum of head generated by each individual stage is cumulative; hence, the total head developed by a multi-stage system increases linearly from the first to the last stage of the pump 206.
In this example, a pump motor protector 210 is coupled to the intake 208 and to a pump motor 212. The pump motor 212, generally, provides mechanical power required to drive the pump 206 via a shaft. As shown in this example, the pump motor 212 is an electric motor that receives electric power through a pump power cable 216 that extends through the annulus 60 (and through the wellbore seal 55) to electrically couple to the pump motor 212. Thus, in this example, the pump power cable 216 provides electrical power from the terranean surface 12 to the pump motor 212. The pump motor protector 210, in this example, operates to absorb a thrust load from the pump 206, transmits power from the motor 212 to the pump 206, equalizes pressure, provides/receives additional motor oil as the motor temperature changes, and prevents wellbore fluid from entering the pump motor 212.
Certain pump motor operational parameters, such as pump intake and discharge pressures, motor oil and winding temperature, and vibration may be measured by the monitoring sub-assembly 214 that is directly coupled to a downhole end of the pump motor 212 in this example implementation. The monitoring sub-assembly 214, in this example, may communicate such measured parameters to the terranean surface 12 through the pump power cable 216.
In alternative implementations of the downhole tool 200, the pump motor 212 may be positioned uphole of the pump 206 in the tool 200. For example, the production unit 202 may include an inverted ESP, such that the pump motor 212 is uphole of the pump motor protector 210, which is uphole of the pump 206. In other alternative implementations, the downhole tool 200 may be deployed on a wireline or other cable downhole conveyance (in a regular or inverted order) rather than the production tubing 17.
As shown in
Directly coupled to the spooler motor protector 220 is a spooler motor 222. The spooler motor 222, in this example, is an electric motor that includes a motor shaft coupled to a shaft of a cable spooler 224 coupled to the downhole end of the spooler motor 222. The spooler motor 222, in this example, provides the mechanical power to rotate the shaft of the cable spooler 224 to unwind a logging cable 230. In some aspects, the electrical power to drive the spooler motor 222 is provided from the terranean surface 12 via by a spooler power cable 226 dedicated for the spooler motor 222. Alternatively, the spooler power cable 226 can be eliminated and electric power to the spooler motor 222 can be provided via an addressable power unit via the pump power cable 216.
In the illustrated implementation, there may be little or no pump thrust load to be handled by the spooler motor protector 220. Thus, in some aspects, no thrust bearing or a very low-capacity thrust bearing may be used in the spooler motor protector 220 to take up any residual thrust loads. In some aspects, the spooler motor protector 220 may operate primarily to equalize pressure, provide/receive additional oil to/from the spooler motor 222 as temperature changes, and prevent wellbore fluid from entering the spooler motor 222.
Coupled to the spooler motor 222 is a cable spooler 224 on which a length of the logging cable 230 (shown in
As shown in
In this example, the logging cable 230 may be a fiber optic logging cable. For example, the fiber optic logging cable can be a single mode or multimode cable, but in the preferred implementation, a multimode fiber optic cable may be used. In some aspects, logging data may be communicated to the terranean surface 12 via either a dedicated fiber embedded in the spooler motor power cable 226. Alternatively, a laser source for the fiber optic cable and electronics may be included to convert a light pulse to an electronic signal and incorporated in a housing just above the cable spooler 224.
In some alternative aspects, logging data may be transmitted electrically via communication over power on the spooler motor power cable 226. For example, if the fiber optic cable is carried via an embedded fiber optic in the spooler motor power cable 226 to the terranean surface 12, the laser light source could be located at the terranean surface 12. Further, electronic signal processing for the received logging data may occur at the terranean surface 12. In some aspects, a fiber optic rotary union (for example, by Moog Inc.) may be used at the cable spooler 224 to allow the transmission of the light from a stationary fiber optic cable as part of the spooler motor power cable 226 to the logging cable 230 that moves and rotates on the cable spooler 224.
As shown in
In an example operation illustrated in
In some aspects, downhole tool 200, which includes the pump 206 within the production unit 202, may be used for subterranean formations that do not have sufficient natural drive (for example, pressure difference between formation pressure and the wellbore 20) to lift wellbore fluid into the production unit 202 (and through the production tubing 17) to the terranean surface 12. Alternatively, in some aspects, the downhole tool 200 may be used in reservoirs with some natural drive, but the pump 206 of the production unit 202 is used to boost production (for instance, flow rate) of the production fluid 50 to the terranean surface 12.
In this example, the downhole tool 300 is positioned just uphole of perforations 65 that have been formed (for instance, shot) in the production casing 35. As shown in this example, downhole tool 300 is positioned downhole of a wellbore seal 55 (for example, a packer, bridge plug, or other wellbore seal) within the annulus 60 of the wellbore 20. The production tubing 17 extends through the wellbore seal 55 and to the surface. The wellbore seal 55, therefore, creates a production zone of the wellbore 20 downhole of the seal 55, and wellbore fluids (such as production fluid 50) are not fluidly communicated from the production zone uphole of the wellbore seal 55.
In this example implementation of the downhole tool 300, the production unit 302 includes an intake 308, but not a pump (or other artificial lift device). The intake 308 includes one or more apertures (for example, adjustable to open and close or fixed in an open position) that fluidly couples the production unit 302 (and thus the production tubing 17) with the annulus 60 of the wellbore 20. The intake 308 may receive a wellbore fluid therein to communicate the fluid to the terranean surface 12 during operation. For example, in some aspects, the downhole tool 300 with production unit 302 may be used in reservoirs with sufficient natural energy (for instance, difference in formation pressure vs. annulus pressure) to drive the wellbore fluid into the intake 308 and up the production tubing 17 to the terranean surface 12.
As shown in
In the illustrated implementation, there may be little or no pump thrust load to be handled by the spooler motor protector 320. Thus, in some aspects, no thrust bearing or a very low-capacity thrust bearing may be used in the spooler motor protector 320 to take up any residual thrust loads. In some aspects, the spooler motor protector 320 may operate primarily to equalize pressure, provide/receive additional oil to/from the spooler motor 322 as temperature changes, and prevent wellbore fluid from entering the spooler motor 322.
Coupled to the spooler motor 322 is a cable spooler 324 on which a length of the logging cable 330 (shown in
As shown in
In this example, the logging cable 330 may be a fiber optic logging cable. For example, the fiber optic logging cable can be a single mode or multimode cable, but in the preferred implementation, a multimode fiber optic cable may be used. In some aspects, logging data may be communicated to the terranean surface 12 via either a dedicated fiber embedded in the spooler motor power cable 326. Alternatively, a laser source for the fiber optic cable and electronics may be included to convert a light pulse to an electronic signal and incorporated in a housing just above the cable spooler 324.
In some alternative aspects, logging data may be transmitted electrically via communication over power on the spooler motor power cable 326. For example, if the fiber optic cable is carried via an embedded fiber optic in the spooler motor power cable 326 to the terranean surface 12, the laser light source could be located at the terranean surface 12. Further, electronic signal processing for the received logging data may occur at the terranean surface 12. In some aspects, a fiber optic rotary union (for example, by Moog Inc.) may be used at the cable spooler 324 to allow the transmission of the light from a stationary fiber optic cable as part of the spooler motor power cable 326 to the logging cable 330 that moves and rotates on the cable spooler 324.
As shown in
In an example operation illustrated in
Method 600 may continue at step 604, which includes positioning the downhole tool in the wellbore adjacent a subterranean formation. For example, once in the wellbore 20, the downhole tool 200 or the downhole tool 300 may be positioned at or near a subterranean formation, such as formation 40, from which a wellbore fluid is produced. In some aspects, the wellbore fluid is a hydrocarbon fluid, such as oil, gas, or a mixed phases of oil and gas. Alternatively, the subterranean formation may produce another fluid, such as brine. In some aspects, as part of step 604 (or just subsequent to step 604), a wellbore seal, such as packer 55, may be set in the wellbore uphole of the positioned downhole tool in order to define a production zone downhole of the wellbore seal. Wellbore fluid downhole of the wellbore seal, therefore, may not pass through the annulus 60 of the wellbore 20 across the seal.
Method 600 may continue at step 606, which includes unspooling a cable from the logging tool in a direction downhole of the downhole tool. For example, once the downhole tool 200 or downhole tool 300 is at the desired position, a logging operation may commence with a logging unit (unit 204 or 304, respectively) of the downhole tool 200 or 300. As described, the logging cable may be unspooled from a cable spooler (224 or 324) through operation of a spooler motor (222 or 322) that is rotatably coupled to the cable spooler. In some aspects, power to the spooler motor may be received from a spooler motor power cable (226 or 326) that extends to the logging unit from the terranean surface 12. Alternatively, power to the spooler motor may be received from a pump power cable 216 that extends to the production unit from the terranean surface 12. In still other aspects, power to the spooler motor may be received from a power source internal to the downhole tool, such as a battery or other stored electrical energy source.
In some aspects, unspooling the logging cable also includes maintaining the logging cable relatively concentric with a radial centerline axis of the wellbore 20. For example, a weight (228 or 328) may be placed on an end of the logging cable and exert a force in a downhole direction (due to gravity) to keep the logging cable relatively centered in the wellbore 20, as well as taut.
Method 600 may continue at step 608, which includes logging at least a portion of the wellbore with the unspooled cable. For example, the logging cable, in some aspects, may include or be a fiber optic logging cable that includes one or more sensors. Such sensors include, for example, pressure, temperature, resistivity, gamma, or sonic to name a few. Logging data from the subterranean formation 40, the wellbore fluid, or both, may be measured by the one or more sensors. In some aspects, step 608 also includes transmitting such measured data to the terranean surface 12. For example, the measured logging data may be transmitted to the terranean surface 12 on a dedicated fiber optic cable that extends from the logging unit to the surface 12, or within the spooler motor power cable (or other power cable) that extends from the downhole tool 200 or 300 to the terranean surface 12. Alternatively, such measured data may be stored (for example, in a non-transitory computer media) within the downhole tool 200 or 300 and later retrieved once the tool 200 or 300 is run out of the wellbore 20 and brought to the surface 12.
Method 600 may continue at step 610, which includes, during logging of the wellbore, producing a wellbore fluid from the wellbore through an inlet of the production unit and into the production conduit or tubing. For example, in the case of the downhole tool 200, the production unit 202 includes a pump assembly (such as an ESP assembly) that includes pump 206 and pump motor 212 (as well as other components as described). The pump motor 212 may operate the pump 206 to circulate the wellbore fluid (for example, production fluid 50) through an intake 208 of the production unit 202 and into the production conduit or tubing 17. Such a scenario may occur, for example, when the subterranean formation 40 does not have sufficient natural drive to produce the wellbore fluid to the terranean surface 12 without artificial lift. In the case of the downhole tool 300, the production unit 302 includes an intake 308, through which wellbore fluid may naturally circulate and enter the production conduit or tubing 17 to be produced to the terranean surface 12. Such a scenario may occur, for example, when the subterranean formation 40 has sufficient natural drive to produce the wellbore fluid to the terranean surface 12 without artificial lift.
In some aspects, the steps of method 600 may be performed in a different order without departing from the scope of the present disclosure. For example, step 610 may be performed between steps 604 and 606. Thus, in some aspects, the production step 610 may begin prior to the logging steps 606-608, and continue during the logging steps 606-608. Alternatively, in some aspects, the logging steps 606-608 may be performed absent the production step 610. In other aspects, the production step 610 may be performed absent the logging steps 606-608. In some aspects, steps 606-608 may be performed prior to step 610, may not be performed during the performance of step 610, but may be performed again subsequent to the production step 610.
In this example, the downhole tool 700 is configured to be positioned in the horizontal portion 22 just uphole of perforations 66 that have been formed (for instance, shot) in the production casing 35.
In this example implementation of the downhole tool 700, the production unit 702 includes a pump 706. In some aspects, the pump 706 is an electrical submersible pump (ESP) (ESP 706). Alternatively, the pump 706 may be a progressive cavity pump, centrifugal pump, or other downhole artificial lift device that obstructs access to the subterranean formation 40 for logging purposes. The pump 706, in this example, is used to lift wellbore fluids (for example, production fluid 50) to the terranean surface 12, or if at or near the terranean surface 12, transfers fluid from one location to another.
Directly downhole of the pump 706 in the production unit 702 is an intake 708. The intake 708 includes one or more apertures (for example, adjustable to open and close or fixed in an open position) that fluidly couples the pump 706 with the annulus 60 of the wellbore 21. The pump 706, in fluid communication with the annulus 60 through the intake 708, may then receive a wellbore fluid therein to lift the fluid to the terranean surface 12 during operation.
In some aspects, the pump 706 includes one or more stages, each of which comprises an impeller and a diffuser. An impeller, which is rotating, adds energy to the wellbore fluid received into the intake 708 to provide head. The diffuser, which is stationary, converts the kinetic energy of the wellbore fluid from the impeller into head. In some aspects, the pump stages are stacked in series to form a multi-stage system that is contained within the pump 706. The sum of head generated by each individual stage is cumulative; hence, the total head developed by a multi-stage system increases linearly from the first to the last stage of the pump 206.
In this example, a pump motor protector 710 is coupled to the intake 708 and to a pump motor 712. The pump motor 712, generally, provides mechanical power required to drive the pump 706 via a shaft. As shown in this example, the pump motor 712 is an electric motor that receives electric power through a pump power cable 716 that extends through the annulus 60 (and through the wellbore seal 55) to electrically couple to the pump motor 712. Thus, in this example, the pump power cable 716 provides electrical power from the terranean surface 12 to the pump motor 712. The pump motor protector 710, in this example, operates to absorb a thrust load from the pump 706, transmits power from the motor 712 to the pump 706, equalizes pressure, provides/receives additional motor oil as the motor temperature changes, and prevents wellbore fluid from entering the pump motor 712.
Certain pump motor operational parameters, such as pump intake and discharge pressures, motor oil and winding temperature, and vibration may be measured by the monitoring sub-assembly 714 that is directly coupled to a downhole end of the pump motor 712 in this example implementation. The monitoring sub-assembly 714, in this example, may communicate such measured parameters to the terranean surface 12 through the pump power cable 716.
In alternative implementations of the downhole tool 700, the pump motor 712 may be positioned uphole of the pump 706 in the tool 700. For example, the production unit 702 may include an inverted ESP, such that the pump motor 712 is uphole of the pump motor protector 710, which is uphole of the pump 706. In other alternative implementations, the downhole tool 700 may be deployed on a wireline or other cable downhole conveyance (in a regular or inverted order) rather than the production tubing 17.
As shown in
Directly coupled to the spooler motor protector 720 is a spooler motor 722. The spooler motor 722, in this example, is an electric motor that includes a motor shaft coupled to a shaft of a cable spooler 724 coupled to the downhole end of the spooler motor 722. The spooler motor 722, in this example, provides the mechanical power to rotate the shaft of the cable spooler 724 to unwind a logging cable 735. In some aspects, the electrical power to drive the spooler motor 722 is provided from the terranean surface 12 via a spooler power cable 726 dedicated for the spooler motor 722. Alternatively, the spooler power cable 726 can be eliminated and electric power to the spooler motor 722 can be provided via an addressable power unit via the pump power cable 716.
In the illustrated implementation, there may be little or no pump thrust load to be handled by the spooler motor protector 720. Thus, in some aspects, no thrust bearing or a very low-capacity thrust bearing may be used in the spooler motor protector 720 to take up any residual thrust loads. In some aspects, the spooler motor protector 720 may operate primarily to equalize pressure, provide/receive additional oil to/from the spooler motor 722 as temperature changes, and prevent wellbore fluid from entering the spooler motor 722.
Coupled to the spooler motor 722 is a cable spooler 724 on which a length of the logging cable 730 (shown in
As described earlier with reference to
In such implementations, the downhole tool 700 includes a tractor 732 to which an end of the logging cable 730 is attached and that can travel (e.g., crawl) the horizontal portion 22 or any deviated portion of the wellbore 21. Power to operate the tractor 732 can be received from the same electrical power source that provides power to drive the spooler motor 722. For example, the electrical power to drive the tractor 732 can be provided from the terranean surface 12 via an umbilical cable (not shown) dedicated for the tractor 732. Alternatively, the umbilical cable can be eliminated and electric power to power the tractor 732 can be provided via an addressable power unit via the pump power cable 716. In some implementations, the tractor 732 can be actuated hydraulically, rather than electrically, or by a combination of hydraulic and electrical power. For example, a hydraulic actuation mechanism can be implemented as a redundancy in case the electrical actuation mechanism does not work, and vice versa. In some implementations, upon receiving electrical power, a hydraulic actuation mechanism can be triggered to perform certain operations of the tractor 732.
In some implementations, the tractor 732 includes a tractor body 734, a pair of extendable/retractable arms (one arm 736 shown in
After the logging unit 704 is lowered to the desired depth in the vertical portion of the wellbore 21 (e.g., the maximum possible depth to which the logging unit 704 can be lowered in the vertical portion), the tractor 732 is activated. Activating the tractor 732 can include providing electrical power or hydraulic power or both, as described earlier. When so activated, the tractor body 734 separates from the cable spooler 724 as the cable spooler 724 unspools the logging cable 230. The tractor 732 travels any remaining distance in the vertically downhole direction under the weight of the tractor 732. Upon contacting a surface within the wellbore beyond which gravity cannot assist with downhole travel, e.g., an entrance to the horizontal portion 22 of the wellbore 21, the arms of the tractor 732 can extend away from the tractor body 734. In some implementations, the arms of the tractor 732 can be extended while the tractor 732 is in the vertical portion of the wellbore 21. In some implementations, load sensors can be deployed in the spooler. When the tractor is being released under gravity, a certain tension on the spooled cable is observed. When the tractor reaches the end of the vertical section of the wellbore, it makes contact with walls of the wellbore, at which time a different tension is observed. The arms of the tractor can be extended when the tension observed by the sensors is determined.
In some implementations, the arms of the tractor are actuated hydraulically to extend and retract. Alternatively or in addition, the arms can be actuated using electrical power. As the arms extend, the wheels are also moved away from the tractor body 734. The extending wheels contact an inner surface 740 within the horizontal portion 22 beyond which the arms can no longer extend. The wheels then begin to turn causing the tractor 732 to travel within the horizontal portion 22 of the wellbore. Instructions to control the direction of movement of the tractor 732, more specifically to control the direction in which the wheels turn, can be transmitted from the terranean surface 12. In implementations in which the logging tool 704 is to be operated during production, the arms can be extended until the wheels press against the inner surface 740, thereby anchoring the tractor body 734 within the horizontal portion 22 of the wellbore 20. The maximum extension of the tractor (i.e., the maximum distance by which the arms can be radially extended away from the tractor body 734) is known. The internal diameter of the wellbore is typically less than or equal to the maximum extension. By monitoring the actual extension or percentage extension of the tractor arms and comparing the extension with the inner diameter or radius of the wellbore, it is possible to ascertain that the wheels have made contact with the inner walls of the wellbore. Alternatively or in addition, load sensors may be incorporated in the wheel section. Impact of the wheels on the wellbore wall register a reaction force on the sensor indicating that the wheels have made contact with the wellbore wall.
Once logging has been completed, the tractor 732 can be operated to travel in reverse, i.e., in an uphole direction toward the entrance to the horizontal portion 22. For example, the wheels can be turned in a reverse direction. In some implementations, the cable spooler 724 can also be operated, i.e., simultaneously with the turning of the wheels, to drag the tractor 732 towards the logging unit 704. Alternatively or in addition, the wheels can be placed in a neutral position in which the wheels can turn freely, and the tractor 732 can be retracted solely by operating the cable spooler 724. In some implementation, the arms of the tractor 732 can be retracted such that the wheels no longer contact the inner surface 22 of the horizontal portion 22. The cable spooler 724 is operated to retract the logging cable 230, and with the logging cable 230, the tractor 732. In this manner, one or combinations of techniques can be implemented to retract the tractor 732 to the cable spooler 724. When the tractor 732 is fully retracted to the cable spooler 724, the tractor 732 and the cable spooler 724 can engage (e.g., using latching/unlatching mechanisms or magnetic or mechanical couplings) to re-attach the tractor 732 to the cable spooler 724.
In this example, the logging cable 730 may be a fiber optic logging cable. For example, the fiber optic logging cable can be a single mode or multimode cable, but in the preferred implementation, a multimode fiber optic cable may be used. In some aspects, logging data may be communicated to the terranean surface 12 via either a dedicated fiber embedded in the spooler motor power cable 726. Alternatively, a laser source for the fiber optic cable and electronics may be included to convert a light pulse to an electronic signal and incorporated in a housing just above the cable spooler 724.
In some alternative aspects, logging data may be transmitted electrically via communication over power on the spooler motor power cable 726. For example, if the fiber optic cable is carried via an embedded fiber optic in the spooler motor power cable 726 to the terranean surface 12, the laser light source could be located at the terranean surface 12. Further, electronic signal processing for the received logging data may occur at the terranean surface 12. In some aspects, a fiber optic rotary union (for example, by Moog Inc.) may be used at the cable spooler 724 to allow the transmission of the light from a stationary fiber optic cable as part of the spooler motor power cable 726 to the logging cable 230 that moves and rotates on the cable spooler 224.
As shown in
Method 800 continues at step 804, which includes positioning the downhole tool in the wellbore adjacent a subterranean formation. For example, once in the wellbore 21, the downhole tool 700 can be positioned in the vertical portion of the wellbore 21, near a subterranean formation, such as formation 40, from which a wellbore fluid is produced. In some aspects, the wellbore fluid is a hydrocarbon fluid, such as oil, gas, or a mixed phases of oil and gas. Alternatively, the subterranean formation may produce another fluid, such as brine. In some aspects, as part of step 804 (or just subsequent to step 804), a wellbore seal, such as packer 55, may be set in the wellbore uphole of the positioned downhole tool in order to define a production zone downhole of the wellbore seal. Wellbore fluid downhole of the wellbore seal, therefore, may not pass through the annulus 60 of the wellbore 21 across the seal.
Method 800 may continue at step 806, which includes unspooling a cable from the logging tool in a direction downhole of the downhole tool. For example, once the downhole tool 700 is at the desired position, a logging operation can commence with a logging unit (unit 704) of the downhole tool 700. As described, the logging cable can be unspooled from a cable spooler 724 through operation of a spooler motor 722 that is rotatably coupled to the cable spooler. In some aspects, power to the spooler motor can be received from a spooler motor power cable 726 that extends to the logging unit from the terranean surface 12. Alternatively, power to the spooler motor can be received from a pump power cable 716 that extends to the production unit from the terranean surface 12. In still other aspects, power to the spooler motor can be received from a power source internal to the downhole tool, such as a battery or other stored electrical energy source.
In some aspects, unspooling the logging cable also includes maintaining the logging cable relatively concentric with a radial centerline axis of the vertical portion of the wellbore 21. For example, the tractor 732 to which an end of the logging cable is attached can exert a force in a downhole direction (due to gravity) to keep the logging cable relatively centered in the wellbore 21, as well as taut.
Method 800 continues at step 808, which includes carrying the cable through the horizontal portion. For example, an end of the logging cable is attached to a tractor, e.g., tractor 732, which, in turn, is attached to the downhole end of the downhole tool 700, specifically, to the logging unit 704. As described earlier, the tractor can detach from the downhole tool 700 and travel vertically downward through the vertical portion of the wellbore 21 under gravity. Upon reaching the entrance to the horizontal portion, the tractor is controlled to travel through the horizontal portion while the tractor is attached to the end of the logging cable. As described earlier, the tractor includes a tractor body, multiple extendable/retractable arms attached to the tractor body, and multiple wheels, each attached to a respective arm. After the tractor reaches the entrance to the horizontal portion, the arms are extended until each wheel on each arm contacts an inner surface of the horizontal portion. Then, each wheel is rotated to cause the tractor to travel through the horizontal portion. In step 808, each wheel is rotated to cause the tractor to travel in the downhole direction through the horizontal portion of the wellbore.
Method 800 continues at step 810, which includes logging within the horizontal portion of the wellbore with the unspooled cable. For example, the logging cable, in some aspects, can include or be a fiber optic logging cable that includes one or more sensors. Such sensors include, for example, pressure, temperature, resistivity, gamma, or sonic to name a few. Logging data from the subterranean formation 40, the wellbore fluid, or both, may be measured by the one or more sensors. In some aspects, step 808 also includes transmitting such measured data to the terranean surface 12. For example, the measured logging data may be transmitted to the terranean surface 12 on a dedicated fiber optic cable that extends from the logging unit to the surface 12, or within the spooler motor power cable (or other power cable) that extends from the downhole tool 700 to the terranean surface 12. Alternatively, such measured data may be stored (for example, in a non-transitory computer media) within the downhole tool 700 and later retrieved once the tool 700 is run out of the wellbore 21 and brought to the surface 12.
In some aspects, during logging of the horizontal portion of the wellbore, a wellbore fluid can be produced from the wellbore through an inlet of the production unit and into the production conduit or tubing. In such aspects, the tractor can be anchored in the horizontal portion to remain in position against the force of the flowing wellbore fluid. To do so, the arms of the tractor can be extended as far radially as possible to increase/maximize the contact between the wheels and the inner surface.
Method 800 can continue at step 812, which includes carrying the cable through the horizontal portion in an uphole direction after logging. For example, each wheel of the tractor can be rotated to carry the tractor in an uphole direction toward the downhole tool 700. After the tractor reaches the entrance to the horizontal portion, the arms of the tractor can be retracted. The logging cable can be spooled in a reverse direction, thereby raising the tractor towards the logging unit. Upon reaching the logging unit, the tractor can be re-attached to the downhole tool. In some aspects, the steps of method 800 may be performed in a different order without departing from the scope of the present disclosure.
In such implementations, the downhole tool 900 includes a receptacle 940 that attaches to the downhole end of the production unit 902 (specifically, to the monitoring sub 914). The downhole tool 900 also includes a tractor 942 attached to the downhole end of the receptacle 940. The receptacle 940 and the tractor 942 can be attached/detached/re-attached by a magnetic or mechanical coupler or by any other coupling mechanism. In some aspects, the receptacle 940 receives power from the terranean surface 12 via a receptacle power cable 941. Alternatively or in addition, an addressable power source to power the receptacle 940 can be mounted to the downhole tool 900 and transported into the wellbore 21 with the tool 900.
In some implementations, the tractor 942 is substantially similar to the tractor 732 described earlier with reference to
The tractor 942 can be deployed in response to receiving a signal, either from the terranean surface 12 or from a controller positioned downhole within the wellbore 21, e.g., mounted to the downhole tool 900. In response to receiving the signal, the tractor 942 is activated. Activating the tractor 942 can include providing electrical power or hydraulic power or both, as described earlier with reference to tractor 732. When so activated, the arms of the tractor are actuated (hydraulically or using electrical power). As the arms extend, the wheels are also move away from the tractor body 944. The extending wheels contact an inner surface 943 within the vertical portion beyond which the arms can no longer extend. The wheels then begin to turn causing the tractor 942 to travel in the downhole direction of the wellbore 21. Instructions to control the direction of movement of the tractor 942, more specifically to control the direction in which the wheels turn, can be transmitted from the terranean surface 12 or from the controller within the wellbore 21, as described earlier. In this manner, the tractor 942 can travel towards the entrance to the horizontal portion 22 while being detached from the rest of the downhole tool 900. In alternative aspects, knowing the length of the vertical portion, an operator can lower the downhole tool 900 to the lowest point of the vertical portion. In such aspects, activating the tractor 944 can simply cause the receptacle 940 to release the tractor 944 without extending the arms. Thus, several methods can be implemented to wirelessly transport the tractor 944 to the entrance to the horizontal portion 22. In some implementations, the tool can be lowered to the lowest point in the vertical portion, and the tractor can be detached from the tool, allowing the tractor to free fall a very short distance to the entrance of the horizontal portion. Sensors can be deployed to determine that the tool is at the lowest position in the vertical portion to minimize a free-fall distance of the detached tractor. For example, a depth/pressure sensor can determine vertical depth based on static pressure which can be a measure of the depth for a fluid of known density.
After the tractor 942 has reached the entrance to the horizontal portion, the tractor 942 can travel into and through the horizontal portion in the same way as tractor 732. Upon reaching a desired downhole location, the tractor 942 can initiate logging operation in the same way as described earlier with reference to
Whereas, in the implementation described with reference to
Method 1000 continues at step 1004, which includes positioning the downhole tool in the wellbore adjacent a subterranean formation. For example, once in the wellbore 21, the downhole tool 1000 can be positioned in the vertical portion of the wellbore 21, near a subterranean formation, such as formation 40, from which a wellbore fluid is produced. In some aspects, the wellbore fluid is a hydrocarbon fluid, such as oil, gas, or a mixed phases of oil and gas. Alternatively, the subterranean formation may produce another fluid, such as brine. In some aspects, as part of step 1004 (or just subsequent to step 1004), a wellbore seal, such as packer 55, may be set in the wellbore uphole of the positioned downhole tool in order to define a production zone downhole of the wellbore seal. Wellbore fluid downhole of the wellbore seal, therefore, may not pass through the annulus 60 of the wellbore 21 across the seal.
Method 1000 may continue at step 1006, which includes detaching a tractor from a receptacle, both mounted on the downhole tool. For example, once the downhole tool 900 is at the desired position, power can be transmitted through the cable 941 to activate the receptacle 940 to which the tractor 942 is attached. Such activation causes tractor 942 to detach from the receptacle 940. Before detaching, the arms of the tractor 942 can be extended away from the tractor body 944, as described earlier, until the wheels of the tractor 942 contact the inner surface 943 of the vertical portion of the wellbore.
Method 1000 continues at step 1008, which includes carrying the tractor into the horizontal portion of the wellbore. As described earlier, the tractor can detach from the receptacle 940 and travel vertically downward through the vertical portion of the wellbore 21 by the turning of the wheels that contact the inner surface 943 of the vertical portion. Upon reaching the entrance to the horizontal portion, the tractor is further controlled to travel through the horizontal portion. The wheels of the tractor continue to engage (i.e., contact and press against) the inner surface of the wellbore as the tractor turns from the vertical portion into the horizontal portion of the wellbore 21. Then, each wheel continues to rotate to cause the tractor to travel through the horizontal portion. In step 1008, each wheel is rotated to cause the tractor to travel in the downhole direction through the horizontal portion of the wellbore.
Method 1000 continues at step 1010, which includes logging within the horizontal portion of the wellbore with sensors mounted to the tractor. For example, the tractor, in some aspects, can include or carry one or more sensors. Such sensors include, for example, pressure, temperature, resistivity, gamma, or sonic to name a few. Logging data from the subterranean formation 40, the wellbore fluid, or both, may be measured by the one or more sensors. In some aspects, step 1008 also includes transmitting such measured data to the terranean surface 12. For example, the measured logging data may be transmitted to the terranean surface 12 via wireless telemetry techniques. Alternatively, such measured data may be stored (for example, in a non-transitory computer media) within the tractor body 944 and later retrieved once the tool 900 is run out of the wellbore 21 and brought to the surface 12.
In some aspects, during logging of the horizontal portion of the wellbore, a wellbore fluid can be produced from the wellbore through an inlet of the production unit and into the production conduit or tubing. In such aspects, the tractor can be anchored in the horizontal portion to remain in position against the force of the flowing wellbore fluid. To do so, the arms of the tractor can be extended as far radially as possible to increase/maximize the contact between the wheels and the inner surface.
Method 1000 can continue at step 1012, which includes carrying the tractor through the horizontal portion in an uphole direction after logging. For example, each wheel of the tractor can be rotated to carry the tractor in an uphole direction toward the downhole tool 900. After the tractor reaches the entrance to the horizontal portion, the wheels continue to rotate causing the tractor to turn from the horizontal portion into the vertical portion of the wellbore 21. The tractor continues to travel in the uphole direction in the vertical portion of the wellbore until the tractor reaches the receptacle, where the tractor reattaches to the receptacle. In some aspects, the steps of method 1000 may be performed in a different order without departing from the scope of the present disclosure.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described herein may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. Accordingly, other implementations are within the scope of the following claims.
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