Patent Application
20250003335
Hydrocarbons are located in porous rock formations beneath the surface of the Earth. Wells are drilled into these formations to access and produce the hydrocarbons. Wells are drilled using a drill string having a drill bit. The drill string breaks away rock and drilling fluid removes the rock from the reservoir. Wells are supported by casing strings cemented in place in the wellbore. In order to safely and effectively drill and case a well, downhole data acquisition is required. Downhole data is acquired in a myriad of ways, however, current methods of obtaining downhole data are deficient. For example, current methods are used to estimate the data, are performed after a section of the well has been drilled, or only measure near-bit depth data.
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
This disclosure presents, in accordance with one or more embodiments methods and systems for a well having a drill string, an annulus, and a drilling fluid. The system includes a drilling microchip, a mud return line, a magnetic sensor, and a computer system. The drilling microchip has a magnet and is configured to be pumped into the drill string and up the annulus using the drilling fluid to obtain data about the well. The mud return line is hydraulically connected to the annulus of the well and a shale shaker. The magnetic sensor is connected to the shale shaker and has a detection range. The magnetic sensor is configured to interact with the magnet to indicate a presence of the drilling microchip in the detection range. The computer system is electronically connected to the microchip detector. The magnetic sensor is configured to send a signal to the computer system upon indication of the presence of the drilling microchip.
The method includes pumping a drilling microchip, having a magnet, into the drill string and up the annulus of the well using the drilling fluid, measuring and storing data about the well using the drilling microchip, and pumping the drilling microchip out of the well to a shale shaker using a mud return line. The method further includes indicating a presence of the drilling microchip in a detection range of a magnetic sensor by having an interaction between the magnetic sensor and the magnet, wherein the magnetic sensor is connected to the shale shaker and sending a signal from the magnetic sensor to a computer system upon indication of the presence of the drilling microchip.
Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.
Specific embodiments of the disclosed technology will now be described in detail with reference to the accompanying figures. Like elements in the various figures are denoted by like reference numerals for consistency. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn are not necessarily intended to convey any information regarding the actual shape of the particular elements and have been solely selected for ease of recognition in the drawing.
In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.
Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.
The drill string (108) may include one or more drill pipes (109) connected to form conduit and a bottom hole assembly (BHA) (110) disposed at the distal end of the conduit. The BHA (110) may include a drill bit (112) to cut into the subsurface rock. The BHA (110) may include measurement tools, such as a measurement-while-drilling (MWD) tool (114) and logging-while-drilling (LWD) tool 116. Measurement tools (114, 116) may include sensors and hardware to measure downhole drilling parameters, and these measurements may be transmitted to the surface using any suitable telemetry system known in the art. Herein, the term surface is defined as any location located outside of the wellbore (102), such as somewhere on the Earth's surface, on a man-made object located on the Earth's surface, etc. The BHA (110) and the drill string (108) may include other drilling tools known in the art but not specifically shown.
The drill string (108) may be suspended in wellbore (102) by a derrick (118). A crown block (120) may be mounted at the top of the derrick (118), and a traveling block (122) may hang down from the crown block (120) by means of a cable or drilling line (124). One end of the cable (124) may be connected to a drawworks (126), which is a reeling device that may be used to adjust the length of the cable (124) so that the traveling block (122) may move up or down the derrick (118). The traveling block (122) may include a hook (128) on which a top drive (130) is supported.
The top drive (130) is coupled to the top of the drill string (108) and is operable to rotate the drill string (108). Alternatively, the drill string (108) may be rotated by means of a rotary table (not shown) on the drilling floor (131). Drilling fluid (commonly called mud) may be stored in a mud pit (132), and at least one pump (134) may pump the mud from the mud pit (132) into the drill string (108). The mud may flow into the drill string (108) through appropriate flow paths in the top drive (130) (or a rotary swivel if a rotary table is used instead of a top drive to rotate the drill string (108)).
In one implementation, a system (199) may be disposed at or communicate with the well site (100). System (199) may control at least a portion of a drilling operation at the well site (100) by providing controls to various components of the drilling operation. In one or more embodiments, system (199) may receive data from one or more sensors (160) arranged to measure controllable parameters of the drilling operation. As a non-limiting example, sensors (160) may be arranged to measure WOB (weight on bit), RPM (drill string rotational speed), GPM (flow rate of the mud pumps), and ROP (rate of penetration of the drilling operation).
Sensors (160) may be positioned to measure parameter(s) related to the rotation of the drill string (108), parameter(s) related to travel of the traveling block (122), which may be used to determine ROP of the drilling operation, and parameter(s) related to flow rate of the pump (134). For illustration purposes, sensors (160) are shown on drill string (108) and proximate mud pump (134). The illustrated locations of sensors (160) are not intended to be limiting, and sensors (160) could be disposed wherever drilling parameters need to be measured. Moreover, there may be many more sensors (160) than shown in
During a drilling operation at the well site (100), the drill string (108) is rotated relative to the wellbore (102), and weight is applied to the drill bit (112) to enable the drill bit (112) to break rock as the drill string (108) is rotated. In some cases, the drill bit (112) may be rotated independently with a drilling motor. In further embodiments, the drill bit (112) may be rotated using a combination of the drilling motor and the top drive (130) (or a rotary swivel if a rotary table is used instead of a top drive to rotate the drill string (108)). While cutting rock with the drill bit (112), mud is pumped into the drill string (108).
The mud flows down the drill string (108) and exits into the bottom of the wellbore (102) through nozzles in the drill bit (112). The mud in the wellbore (102) then flows back up to the surface in an annular space between the drill string (108) and the wellbore (102) with entrained cuttings. The mud with the cuttings is returned to the pit (132) to be circulated back again into the drill string (108). Typically, the cuttings are removed from the mud, and the mud is reconditioned as necessary, before pumping the mud again into the drill string (108). In one or more embodiments, the drilling operation may be controlled by the system (199).
In order to safely and effectively drill and case a wellbore (102), downhole data acquisition is required. Downhole data is acquired in a myriad of ways, however, current methods of obtaining downhole data are deficient. For example, current methods are used to estimate the data, are performed after a section of the wellbore (102) has been drilled, or only measure near-drill bit (112) depth data. The present disclosure outlines systems and methods that may be used to obtain downhole data of the entire well while the drill string (108) is drilling a wellbore (102).
The drilling microchip (200) is pumped into the inside of the drill string (108) at a surface location (206). The surface location (206) is any location on or above the surface of the Earth, such as a floor of a drilling rig. The drilling microchip (200) is pumped into the inside of the drill string (108) using the drilling fluid. The drilling fluid may be pumped in the well (202) using one or more mud pumps (134).
The drilling microchip (200) is carried downhole through the drill string (108), out the bottom of the drill string (108) (such as through the nozzles of the drill bit (112)), and up the annulus (208) of the well (202). The annulus (208) is the space located between the outside of the drill string (108) and the inside of the well (202). The inside of the well (202) may be defined by the wellbore (102) wall or by the inside of a casing string (204) without departing from the scope of the disclosure herein.
The drilling microchip (200) exits the well (202) using the same fluid path the drilling fluid follows. In accordance with one or more embodiments, the drilling fluid and the drilling microchip (200) exit the annulus (208) of the well (202) using a mud return line (210) that is hydraulically connected to the annulus (208) of the well (202) and at least one shale shaker (212). As the drilling microchip (200) travels through the well (202), the drilling microchip (200) may measure and store downhole data.
The downhole data may include pressure data, temperature data, acoustic data, vibrational data, directional surveys, etc. The drilling microchip (200) may measure data for the entire length of the annulus (208) and the entire length of the drill string (108) as it is being pumped through the drill string (108).
The outer shell (310) may be in a spherical shape as shown in
The microchip battery (300) is used to store energy that may be used to power the other components of the drilling microchip (200). The sensors (302) are used to measure downhole data. The sensors (302) may include any type of sensor known in the art such as acoustic, pressure, vibration, accelerometers, gyroscopic, magnetometer, and temperature sensors.
The memory (306) is used to store the measurements gathered by the sensors (302). The microprocessor (304) is used to operate the drilling microchip (200), and the communication module (308) is used to communicate with an external device, such as a computer system (602) (outlined below in
In accordance with one or more embodiments, the magnet (312) is an AlNiCo magnet (312). An AlNiCo magnet (312) is made of an alloy composed of aluminum, nickel, cobalt, iron, and other trace metals. The casting process of an AlNiCo magnet (312) allows the AlNiCo magnet (312) be made into different sizes and shapes. An AlNiCo magnet (312) has the lowest reversible temperature coefficient and can operate at temperatures up to 600 degrees Celsius.
In accordance with one or more embodiments, the magnet (312) is a Neodymium magnet (312). A Neodymium magnet (312) has a BHmax more than 10 times higher than that of ferrite. A Neodymium magnet (312) has excellent mechanical properties. The working temperature can reach up to 200 degrees Celsius.
In accordance with one or more embodiments, the magnet (312) is a SmCo magnet (312). SmCo magnets (312) are divided into SmCo5 and Sm2Co17 according to their components. Because of the high price of materials, these types of magnets (312) are limited. SmCo magnets (312) have a high magnetic energy product (14-28MGOe), reliable coercivity, and good temperature characteristics. Compared with NdFEB magnets, SmCo magnets (312) are more suitable for working in the high-temperature environment.
The drilling microchip (200) recovery system includes a magnetic sensor (400) connected to the shale shaker (212). The shale shaker (212) is a device used in drilling fluid processing that separates cuttings (502) from the drilling fluid (504). The shale shaker (212) includes a drilling fluid inlet (506) where the drilling fluid (504) containing the cuttings (502) and the drilling microchips (200) enter the shale shaker (212).
The cuttings (502) are the portions of rock that are drilled and removed from the subsurface to create the wellbore (102). The shale shaker (212) uses vibrations and screens (508) to separate the cuttings (502) from the drilling fluid (504). The drilling fluid (504) falls through the holes in the screens (508) to be collected in a hopper (510). The hopper (510) acts as a containment area for the drilling fluid (504). The hopper (510) may be connected to other drilling fluid processing equipment to further condition the drilling fluid (504).
The screens (508) are sized such that the majority of the cuttings (502) are unable to fall through into the hopper (510). The separated cuttings (502) fall off the end of the shale shaker (212) into a cuttings container (not pictured). The drilling microchips (200) are also large enough to avoid falling through the screens into the hopper (510) and also fall off of the end of the shale shaker (212) into the cuttings container.
The magnetic sensor (400) is configured to interact with the magnet (312) in the drilling microchip (200) to indicate a presence of the drilling microchip (200) in a detection range (512) of the magnetic sensor (400). The magnetic sensor (400) may be electronically connected to a computer system (602). The magnetic sensor (400) may send a signal to the computer system (602) upon indication of the presence of the drilling microchip (200) in the detection range (512) of the magnetic sensor (400).
The magnetic sensor (400) may also have an alarm (514) that will create an alert, such as a sound or a light, when the magnetic sensor (400) detects the magnet (312) of the drilling microchip (200). Furthermore, the magnetic sensor (400) may be able to identify the number of drilling microchips (200) passing through the detection range (512) by identifying each magnet (312) as they enter the detection range (512).
In
In
Once the signal is sent to the computer system (602) or the alarm (514) is seen, a person may be alerted to the presence of the drilling microchip (200) in the cuttings container. This person can then retrieve the drilling microchip (200) and extract the measured data from the drilling microchip (200).
As stated above, an interaction between the magnetic sensor (400) and the magnet (312) in the drilling microchip (200) occurs in order to indicate a presence of the drilling microchip (200) in the detection range (512). In accordance with one or more embodiments, the magnetic sensor (400) may be any magnetic sensor (400) known in the art, such as a digital switching magnetic sensor (400), an analog magnetic sensor (400), or a passive magnetic sensor (400).
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include hall effect switches and magnetoresistance sensors. Hall effect switches and magnetoresistance sensors provide a single digital switching output (or relay output) that turns on when a magnetic field is present and off when the magnetic field leaves. When paired with a magnet (312), these magnetic sensors (400) may be used to measure speed, count, position, or alignment between the magnetic sensor (400) and target magnet (312).
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include hall effect latches. Hall effect latches provide a single digital switching output that turns on when a south pole magnetic field is present. The output remains on until a north pole field is detected. The latching output is useful in creating a 50% duty cycle when detecting alternating north and south poles in multi-pole magnet tape and magnet wheels.
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include dual output hall effect switches. Dual output hall effect switches combine a south pole hall switch and a north pole hall switch into a single magnetic sensor (400) with two outputs. These sensors are frequently used in applications where multiple magnets (312) are present. Dual output hall effect switches have one pole for measuring speed of a rotating target and one opposite pole magnet used to index a specific location in the rotation or to provide a once per rotation count.
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include quadrature magnet sensors which provide two digital pulsing outputs. The sensing elements are placed side by side so when a magnet (312) passes in one direction, channel A will switch first, and, when the magnet passes in the opposite direction, channel B will switch first. By comparing the outputs, a tachometer or controller can monitor the speed and direction of movement or perform directional counting.
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include anisotropic magnetoresistance (AMR) sensors. AMR sensors have AMR components whose resistance varies with the strength or direction of the magnetic field. Non-contact rotation or position detection is possible when combined with a magnet (312).
In accordance with one or more embodiments, the digital switching magnetic sensor (400) may include tunnel magnetoresistance (TMR) sensors. TMR sensors may be used to detect the strength of the magnetic field in order to measure current, position, motion, direction, and other physical factors.
In accordance with one or more embodiments, the analog magnetic sensor (400) may include an analog hall sensor. An analog hall sensor provides a single analog output that increases or decreases dependent on the size and pole of the magnetic field at the face of the magnetic sensor (400).
In accordance with one or more embodiments, the analog magnetic sensor (400) may include a linear position sensing system. A linear position sensing system combines a sensor and a specially designed target magnet (312) to provide an analog output that changes based on the alignment of the sensor and the target magnet.
In accordance with one or more embodiments, the analog magnetic sensor (400) may include an angular position sensor. An angular position sensor provides a single analog output that increases or decreases dependent on the rotation of an angle position magnet (312).
The passive magnetic sensor (400) may include reed switches. Reed switches are normally open or normally closed switches that close or open when a magnetic field is present. Reed switches are low cost and easy to use sensors.
Additionally, the computer (702) may include a computer that includes an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer (702), including digital data, visual, or audio information (or a combination of information), or a GUI.
The computer (702) can serve in a role as a client, network component, a server, a database or other persistency, or any other component (or a combination of roles) of a computer system for performing the subject matter described in the instant disclosure. The illustrated computer (702) is communicably coupled with a network (730). In some implementations, one or more components of the computer (702) may be configured to operate within environments, including cloud-computing-based, local, global, or other environment (or a combination of environments).
At a high level, the computer (702) is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer (702) may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers).
The computer (702) can receive requests over network (730) from a client application (for example, executing on another computer (702)) and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer (702) from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers.
Each of the components of the computer (702) can communicate using a system bus (703). In some implementations, any or all of the components of the computer (702), both hardware or software (or a combination of hardware and software), may interface with each other or the interface (704) (or a combination of both) over the system bus (703) using an application programming interface (API) (712) or a service layer (713) (or a combination of the API (712) and service layer (713). The API (712) may include specifications for routines, data structures, and object classes. The API (712) may be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer (713) provides software services to the computer (702) or other components (whether or not illustrated) that are communicably coupled to the computer (702).
The functionality of the computer (702) may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer (713), provide reusable, defined business functionalities through a defined interface. For example, the interface may be software written in JAVA, C++, or other suitable language providing data in extensible markup language (XML) format or other suitable format. While illustrated as an integrated component of the computer (702), alternative implementations may illustrate the API (712) or the service layer (713) as stand-alone components in relation to other components of the computer (702) or other components (whether or not illustrated) that are communicably coupled to the computer (702). Moreover, any or all parts of the API (712) or the service layer (713) may be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of this disclosure.
The computer (702) includes an interface (704). Although illustrated as a single interface (704) in
The computer (702) includes at least one computer processor (705). Although illustrated as a single computer processor (705) in
The computer (702) also includes a non-transitory computer (702) readable medium, or a memory (706), that holds data for the computer (702) or other components (or a combination of both) that can be connected to the network (730). For example, memory (706) can be a database storing data consistent with this disclosure. Although illustrated as a single memory (706) in
The application (707) is an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer (702), particularly with respect to functionality described in this disclosure. For example, application (707) can serve as one or more components, modules, applications, etc. Further, although illustrated as a single application (707), the application (707) may be implemented as multiple applications (707) on the computer (702). In addition, although illustrated as integral to the computer (702), in alternative implementations, the application (707) can be external to the computer (702).
There may be any number of computers (702) associated with, or external to, a computer system containing computer (702), each computer (702) communicating over network (730). Further, the term “client.” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one computer (702), or that one user may use multiple computers (702).
In step 800, a drilling microchip (200), having a magnet (312), is pumped into the drill string (108) and up the annulus (208) of the well (202) using the drilling fluid (504). In accordance with one or more embodiments, the drilling fluid (504) carries the drilling microchip (200) inside of the drill string (108), out the bottom of the drill string (108), through the nozzles of the drill bit (112), and up the annulus (208) of the well (202).
In step 802, data about the well (202) is measured and stored using the drilling microchip (200). As the drilling microchip (200) is carried by the drilling fluid (504), the drilling microchip (200) may use its sensors (302) to gather downhole data about the conditions in the well (202) including pressure data, temperature data, directional surveys, vibrational data, etc. Further, because the drilling microchip (200) is pumped through the entirety of the well (202), the drilling microchip (200) may take measurements at any and all depths of the well (202). The measurements may be stored on the memory (306) of the drilling microchip (200)
In step 804, the drilling microchip (200) is pumped out of the well (202) to a shale shaker (212) using a mud return line (210). The mud return line (210) is hydraulicly connected to the annulus (208) of the well (202) and the shale shaker (212). The shale shaker (212) separates solids, such as cuttings (502), from the drilling fluid (504). Due to the size of the drilling microchips (200), they are also separated from the drilling fluid (504) with the cuttings (502). In order to determine when a drilling microchip (200) has exited the well (202), a magnetic sensor (400) is installed on the shale shaker (212).
In step 806, a presence of the drilling microchip (200) in a detection range (512) of a magnetic sensor (400) is indicated by having an interaction between the magnetic sensor (400) and the magnet (312). As noted above, the magnetic sensor (400) may be a digital switching magnetic sensor (400), an analog magnetic sensor (400), or a passive magnetic sensor (400).
The digital switching magnetic sensor (400) may include hall effect switches integrated with magnetoresistance sensors, hall effect latches, dual output hall effect switches, quadrature magnetic sensors, AMR sensors, or TMR sensors. The analog magnetic sensor (400) may include analog hall sensors, linear position sensing systems, or angular position sensors. The passive magnetic sensors may be reed switches. The magnet (312) may be an AlNiCo magnet (312), a Neodymium magnet (312), or a SmCo magnet (312).
In step 808, a signal is sent from the magnetic sensor (400) to a computer system (602) upon indication of the presence of the drilling microchip (200). In further embodiments, the magnetic sensor (400) triggers an alarm (514). A person may use the alarm (514) or the computer system (602) to be notified of a drilling microchip (200) at the shale shaker (212). Upon notification, the person may retrieve the drilling microchip (200) from the cuttings (502) container. Further, the person may download the data from the drilling microchip (200) using the computer system (602).
Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112 (f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.
