Exploration and production companies operate several thousand producing oil and/or gas wells (on-shore, off-shore, sub-sea, both natural flowing and artificial lift equipped wells). Most of these wells, especially in mature assets, are not equipped with a permanent downhole pressure and/or temperature monitoring sensor. There is a need for suitable instrumentation that can be retrofitted in these existing wells, suitable for long term downhole measurement and preferably able to transmit wirelessly the data to the surface wellhead. Being able to continuously monitor these wells allows for a better understanding of the reservoir's behavior and enable suitable actions to improve reservoir management and production performances.
The control and monitoring of wells has become essential for the optimization of the production and the reduction of interventions in wells. The optimization of the production and reduction of the produced water are critical areas for economic success in offshore wells. As new processes for drilling, completion, production and reservoir management are developed, advancements in technologies related to temperature, pressure, and flow monitoring and downhole device control are required. Reservoir development systems must be constantly monitored to ensure maximum production.
Permanent downhole systems may only be modified, reconfigured or serviced by pulling the entire downhole apparatus out of the wellbore. It is laborious, time-consuming and expensive to pull the entire length of production tubing out of the casing to service and re-install a downhole control system.
Various figures are included herein which illustrate aspects of embodiments of the disclosed inventions.
Sensor technology as described herein used in conjunction with real time data communications techniques can provide on-demand access to the information necessary to optimize hydrocarbon production levels and achieve costs goals. Surface and downhole sensors may be used to change the way hydrocarbons are produced by optimizing production from downhole, supporting and extending the life of artificial lift systems and providing information used to update reservoir and production models.
The claimed invention comprises combining sensors with wireless telemetry to help provide operators with new versatility and capability to place sensors in areas of the wellbore that were prohibitive due to technical difficulties and/or economic justification. Downhole data acquisition systems can also be used to interface with surface control systems utilizing both wireless and cable transmission media. Wireless acoustic signals containing pressure and temperature information can be transmitted from downhole to the surface using a tubing string, such as production pipe or coiled tubing to the surface. Pressure pulses generated downhole such as by chocking a portion of the flow can also be used to transmit digital data to the surface. Electromagnetic energy can be used as the transmission energy using the geological formation or the production tubing as the medium of communications.
In addition, the ability to deploy gauges in existing wells to communicate in and out of the wellbore using through tubing wireless systems can increase the reliability of the production system and eliminate the requirements to remove the completion hardware from the wellbore. The optional elimination of cables, clamps, external pressure and temperature sensors, as well as splices on the cable that can fail inside the wellbore provides a significant advantage over existing gauge technologies. The wireless wellbore digital data communications and sensing system provides the capability to communicate through the production tubing using stress waves to transmit and receive digital data and commands inside the wellbore. The ability to transmit through the fluid as well during production by chocking a small portion of the fluid (pulser) allows for the creation of a pressure pulses that are detected at the surface.
Referring to
Referring additionally to
In this first embodiment, hybrid tool 10 comprises mandrel housing 19 containing various components such as sensors 14, electronics module 16, power store 42 which may comprise one or more backup batteries, downhole tool power generator 17, pressure pulse generator 22, acoustic generator 21, and an interface between one or more gauges and production tubing 101 (
As illustrated in
Hybrid tool 10 further typically comprises wireless wellbore digital data transceiver 30 which is adapted to be disposed within a wellbore of well 100 and further adapted to transmit and receive digital data wirelessly using acoustic compressional waves transmitted though production tubing 101 when a triggering event occurs such as when production pressure of the production fluid drops below a predetermined pressure that prevents use of the digital data pressure pulses, when the well is shut in, when the production fluid does not fill the entire well, or if the conditions in the well prevent fluid pressure from reaching the surface, or the like, or a combination thereof.
Acoustic transmissions may have a transmission range between 6,000 ft and 7,500 feet without a repeater. Pressure pulses may travel in excess of 10,000 ft without a repeater.
In the first embodiment, referring additionally to
Gauge system 15 typically comprises one or more wireless gauges such as wireless gauge 15a and may be sized smaller than an inside diameter of production pipe 101, e.g. less than around 2 inches, to allow production fluids to flow through production pipe 101 even after wireless gauge 15a is installed. Wireless gauge 15a will typically be of a length sufficient to accomplish its measurements, e.g. about 12 feet long.
Sensors 14, which may comprise a pressure sensor, a temperature sensor, or the like, or a combination thereof, may be quartz sensors stable over time with little to no drift or a maximum drift 0.1° C./year and +/−2 psi/year. If present, sensor 14 is typically located at the bottom of hybrid tool 10, typically within mandrel housing 19 (
Electronics module 16 comprises components sufficient to provide data acquisition and to also allow control of acoustic communications and pressure pulse transmissions. Electronics module 16 typically comprises one or more microcontrollers for data collection and creation of proper communications transmission timing as well as non-volatile memory for storage of gathered data. It can also determine if the data to be transmitted to surface location 110 is to be done via pressure pulses or acoustic communications. Electronics module 16 may also manage the power in wireless gauge 15a. Accelerometer or strain gauge 11 will be used to pick up information transmitted from the surface for 2-way communications.
Communications module 20 comprises acoustic generator 21 and pressure pulse generator 22. The acoustic waves generated by wireless gauge 15a travel up production pipe 101 to surface location 110 in a compression mode, minimizing losses related to fluid coupling and tubing threads. The data are detected at surface location 110 such as by using accelerometers or hydrophones. The pressure pulses travel to surface location 110 using the fluid in well 100. A small portion of the fluid being produced will be diverted and chocked by pressure pulser valve 22a to generate a pressure pulse that travels through the fluid to surface location 110. A pressure gauge at the surface detects the pressure pulses and converts them into electrical signals.
In embodiments, pressure pulse generator 22 is configured to transmit digital data through the fluid by choking a small portion of production fluid to create of a pressure pulses that are detected at surface location 110. Pressure pulse generator 22 acts by diverting a small portion of the production fluid through one or more pressure pulser valves 22a that open and close to modulate the flow of fluid going to surface location 110. This modulation causes a variation of pressure that can be picked up by the surface data converter. The communication typically uses a Non-Return-to-Zero technique to reduce the number of bits transmitted to the surface reducing the wear on pressure pulser valves 22a. Pressure pulse generator 22 typically comprises a ceramic material.
Wireless wellbore digital data transceiver 30, which can be an acoustic telemetry tool, transmits vibration frequencies that are unaffected by pump noise or other noise in well 100. Acoustic data are generally transmitted using a broadband multi-frequency signal to account for variances in the acoustic impedance of production tubing 101. As an example, piezo wafers may be used to generate an acoustic signal that are unique and address passbands available in production tubing 101. Passbands are characteristics of a production tubing string which allows for certain inherent frequencies to travel through production tubing 101 with minimal attenuation. A method to reduce the complexity and cost of the downhole gauges is the use a broadband acoustic signal that is composed of most of the frequencies that are normally associated with the efficient data transmission at the pipe diameter.
Referring additionally to
Referring back to
When present, the pressure pulses transmitted from downhole are detected using pressure sensor 211 at the surface in contact with the wellbore fluid and converted into electrical signals that are processed into representative data, e.g. data reflecting pressure and temperature, at the surface by surface system 200.
Data processor 201 collects the data transmitted from downhole using acoustic and/or pressure pulses and process the information into pressure and temperature data. The data is typically stored in high density memory, e.g. one associated with surface system 200, to provide a history of the data collection and well production. The data may also be sent to a remote location for further processing.
Data processor 201 typically comprises one or more data transceivers 202 remotely located with respect to hybrid tool 10 and adapted to wirelessly interchange digital data with wireless wellbore digital data transceiver 30 using the acoustic compressional waves and/or with pressure pulse generators 22 using pressure pulses; one or more data signal detection modules 203; one or more data transmission receivers 204, which can be data transmission transceivers; and software control and data acquisition (SCADA) system 205 configured for data acquisition and processing.
In embodiments, surface system 200 comprises one or more data processor and may use the Internet of Things to collect and transfer data and may be housed in an explosion proof box. Typically, the data processing for acoustic communications uses fast Fourier transform techniques to extract the data from any noise in well 100.
In further embodiments, referring to
In addition, power generator 340 (not specifically shown in the figures but similar to power generator 40) is operatively in communication with gauge system 315 and wireless wellbore digital data transceiver 330, where power generator 316 is operative to supply electrical power to gauge system 315 and wireless wellbore digital data transceiver 330.
As used herein, gauge system 315 comprises one or more individual gauges (basically referred to herein as gauge 315A or 315B) may comprise a pressure gauge, a temperature gauge, or the like, or a combination thereof. Accordingly, gauge system 315 typically comprises a plurality of gauges 315 such as first gauge 315A disposed in first zone 100A within well 100 and second gauge 315B disposed in second zone 100B within well 100, second zone 100B being intermediate first zone 100A and surface location 110. Second gauge 315B may be further configured as data repeater to aid in transmitting the digital data signal to surface location 110. Each gauge comprises a data transmitter configured to allow data transmission up to a maximum data communications distance and gauges 315 are deployed at a distance between each pair of gauges 315 which is within the smaller of the maximum data communications distance those two gauges 315. In embodiments, multiple gauges 315 are deployed within well 100, each gauge 315 being deployed within the maximum communication distance between that gauge 315 and an adjacent gauge 315.
Typically, gauges 15,315 comprise an initial accuracy of ±3 psi for pressure and ±0.5° C. for temperature readings. In addition, gauge system 315 may be disposed in mandrel housing 319 (not specifically called out in the drawings but similar to mandrel housing 19). Material like 13 Cr will be used due to its strength and resistance to the downhole environment. Mandrel housing 319 is typically smaller than 2 inches in diameter for deployment in well 100. Slips 318 (not specifically called out in the drawings but similar to slips 18) are typically present as well.
In these embodiments, surface system 200 is typically present and is as described above.
In most embodiments, pressure pulses typically comprise fluid pressure pulses and wireless wellbore digital data transceiver 30 (
In contemplated embodiments, slips 18 may act as a coupler and operatively be in communication with production tubing 101 to create a path for acoustic pressure pulse digital data signals from a predetermined gauge of gauge system 315 to production tubing 101.
Detector sub 350, which typically comprises an electronics module and/or gauge or the like, may be located inside well 100 and adapted to pick up the transmitted digital data signal; and cable 360, which may be a data transmission cable, may be present as well and operatively in communication with surface location 110 and detector sub 350. Detector sub 350 is typically disposed in well 100 proximate a location below tubing hanger 105 to convert the acoustic signals into electrical data and/or to increase the digital data signal interface with cable 350 to get the data to surface location 110 where it can be picked up at surface location 110 without using a data transmission cable.
Surface system 200 further comprises a digital signal processor adapted to reduce noise in the received digital data signal and extract the digital data signal from noise present in the predetermined medium. In embodiments, surface system 200 typically further comprises an external data transceiver adapted to interface surface system 200 to a system located remotely from surface system 200. In embodiments, surface system 200 is adapted to use a ModBus or an Internet of Things protocol when interfacing with a data processing system located remotely from surface system 200.
In certain embodiments, near surface relay 106 may be present and typically disposed within well 100. Near surface relay 106 is adapted to obtain a transmitted digital data signal from downhole and amplify the transmitted digital data signal so that the transmitted digital data signal can go through tubing hanger 105 and a wellhead to eliminate the need to put a detector in well 100.
In the operation of exemplary methods, referring back to
In embodiments, data will be transmitted wirelessly using acoustic compressional waves transmitted though production tubing 101 and/or pressure pulses generated by pressure pulse generator 22 downhole and transmit them through the production fluid. A downhole environment may not homogeneous and therefore may require different approaches for different wells and for different stages of production. As an example, pressure pulses can be used when the well is being produced to transmit data to the surface. Acoustic energy can be used as the mean for communications when the production pressure drops significantly or when the well is shut in.
Data may be obtained in real time without the need to pull production tubing 101 from well 100 using real time through tubing wireless gauge system 1,3, described above. First gauge 315A may be deployed at a first location within the well proximate first zone 100A within well 100 and second gauge 315B deployed proximate second zone 100B within well 100 at a second location, e.g. one distal from the first location within well 100 intermediate first zone 100A and surface location 101. Gauge system 315 may be installed downhole at relatively low cost because hybrid tool 10 may be lowered in well 100 through the inside of production tubing 101. Accordingly, there may be no need to pull production tubing 101 from well 100 to install a new gauge. In embodiments, gauge system 315 may be deployed in well 100 using a slickline if well 100 is vertical or has a low deviation from vertical. Slips 18 may be set against production tubing 101 like a packer slips to help assure that gauge 315 is secured in its location in well 100. When the gauge 315 reaches a desired location within production pipe 101, an operator may set gauge 315 in place by manipulating a setting tool and locked gauge 315 in a “set” configuration such as by a ratchet spring.
Power supply 340 supplies electrical power to gauge system 315 and wireless wellbore digital data transceiver 330. Data obtained from gauge system 315 is converted into a digital data signal such as by wireless wellbore digital data transceiver 330 which is also used to wirelessly transmit a digital data signal comprising the data using pressure pulses and/or acoustic pressure transmitted through a predetermined medium such as production fluid and/or production pipe 110. A data signal detector, e.g. detector sub 350 or surface converter 210 and/or pressure sensor 211, may then be used to detect the transmitted digital data signal using the pressure pulses transmitted through the predetermined medium. The detected digital signal is then provided to the surface software control and data acquisition (SCADA) system 205 for data acquisition and processing.
As noted above, wireless wellbore digital data transceiver 330 may wirelessly transmit the digital data signal though the predetermined medium by using pressure pulse generator 22 configured to create the digital data signal for communications from downhole to the surface and/or transmit and receive digital data wirelessly using acoustic compressional waves transmitted though production tubing 101 when production pressure of the production fluid drops below a predetermined pressure that prevents use of the digital data pressure pulses or when well 100 is shut in.
In certain methods, one or more gauges 315 may act as a data transceiver and be disposed intermediate a further downhole wireless gauge 315 deployed in well 100 and surface location 110 and used to boost and re-transmit data from wireless gauge 315. Gauges 315 located intermediate surface location 110 and a most distally located gauge 315 can also be downhole gauges where the data from a second gauge disposed immediately below a first gauge is combined with data from the second gauge and transmitted to surface location 110. The same process can be repeated all the way to the surface.
Surface system 200 data transceiver 200 may comprise a pressure pulse generator or an acoustic generator and communicate with a wireless gauge of gauge system 315 through the predetermined medium.
As discussed herein, wireless wellbore digital data transceiver 330 may wirelessly transmit the digital data signal though the predetermined medium by using fluid pressure pulse generator 22 configured to create the digital data signal for communications from downhole to surface location 110 and/or transmit and receive digital data wirelessly using acoustic compressional waves transmitted though production tubing 101 when production pressure of the production fluid drops below a predetermined pressure that prevents use of the digital data pressure pulses or when the well is shut in.
Real-time data may be provided with a sample rate of 1 data per minute. In addition, SCADA system 205 shall gather the data acquired downhole and store them in an internal memory which may be configured to guarantee multiple days of storage capacity.
When or if necessary, one or more gauges of gauge system 315 can be retrieved from well 200 by releasing slips 18 from production pipe 101. Fishing neck 17, typically located on the top of gauge 315 or hybrid tool 10, can be latched to a retrieval tool on a wireline, slickline, or an electric line allowing a surface unit to pull hybrid tool 10. Slips 18 may be released when shear screws 27 located on the lower section of hybrid tool 10 are ruptured.
The foregoing disclosure and description of the inventions are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction and/or an illustrative method may be made without departing from the spirit of the invention.
This application claims priority through U.S. Provisional Application 62/795,487 filed on Jan. 22, 2019.
Number | Date | Country | |
---|---|---|---|
62795487 | Jan 2019 | US |