The present application is a U.S. National Stage patent application of International Patent Application No. PCT/US2016/012587, filed on Jan. 8, 2016, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.
The present disclosure relates generally to downhole sensors and, more specifically, to pre-manufactured sensors adapted to be reeled on a spool.
In the oil and gas industry, downhole sensors are deployed to acquire various characteristics of the formation and wellbore environment. In one application, electromagnetic (“EM”) sensors (transmitters and receivers) are permanently deployed during completion operations along with the casing. For such applications, hundreds of transmitters and receivers will need to be deployed, which is very time-consuming. Given that the cost associated with a wellbore can rise to $400,000 per day, the deployment of the sensors is also a very expensive proposition.
Conventional methods to deploy sensors are inefficient and very time consuming. In the conventional method, a transmitter deployment requires the assembling of a ferrite collar around a tubular at the well site. Once the ferrite collar is attached, an electrical cable is wrapped around the collar to thereby fabricate the transmitter at the wellsite. Thereafter, the tubular is deployed downhole. Thus, the conventional method of fabricating sensors at the well site is very time consuming.
Illustrative embodiments and related methods of the present disclosure are described below as they might be employed in a reelable sensor array for downhole applications. In the interest of clarity, not all features of an actual implementation or method are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Further aspects and advantages of the various embodiments and related methods of the disclosure will become apparent from consideration of the following description and drawings.
As described herein, illustrative systems and methods of the present disclosure are directed to reelable sensors arrays that are independently fabricated separate from a downhole tubular. The sensors are first fabricated and attached to one another using a cable, thereby forming a sensor array. The sensors and cable are then reeled together onto a spool. At the well site, the sensor array is unreeled from the spool and attached to the tubular as it is deployed downhole, thereby removing the need to construct the sensors and make electrical connections at the well site. As a result, a fast and efficient method of sensor deployment is provided.
Each sensor assembly 12a-12c is comprised of a flexible backing 16a-16c, respectively. Flexible backings 16a-c are foldable as shown in
After being reeled onto spool 25, sensor array 10/spool 25 may be transported to a well site. However, in other methods, sensor array 10 may be reeled onto spool 25 at the well site. Nevertheless, once reeled, sensor array 10 is now ready to be attached to a downhole tubular in a quick and efficient manner.
In order to attach this illustrative embodiment of sensor array 10, each flexible backing 16a-c is wrapped around tubular 26. Flexible backing 16 may be secured to tubular 26 in a variety of ways.
In certain illustrative embodiments, flexible backing 16 may be made of an elastomeric type material. As in certain other embodiments described herein, the length of flexible backing 16 will be determined based upon the size of tubular 26. Thus, in embodiments using the elastomeric type material, the length of flexible backing 16 may be a little shorter than that required to completely surround tubular 26. When the shorter flexible backing 16 is wrapped around tubular 26, it is stretched and ends 28A,B are connected. After the connection is made, the elastic flexible backing 26 then compresses against tubular 26, thus securing it. Additionally, with reference to
Moreover, in certain other illustrative embodiments, flexible backing 16 may include a pocket in which sensors 18 are positioned. Depending upon the sensor design utilized, the pockets may be conductive or non-conductive, and may completely or partially cover sensors 18.
As described above, regardless of the securement method used, the present illustrative methods provide a fast and efficient way of deploying downhole sensors along a tubular string. The tubular string may take a variety of forms, including for example, a casing string, production string or drilling string.
Although not shown in
Alternatively, when coils 24 are oriented such that their axes are transverse to the tubular axis, the coils 24 act as an equivalent toroid.
In yet other embodiments, sensors 18 may be azimuthally separated into directionally sensitive groups.
As with other embodiments described herein, the fiber optic sensor arrays 40, 40′ and 40″ are pre-manufactured as shown in
The signal levels of the illustrative embodiments described herein and conventional sensors were simulated and compared.
A model for azimuthally sensitive sensor array was also built and simulated. The azimuthally sensitive sensor(s) were constructed using coils and grouped together as described herein and illustrated in
The illustrative sensors described herein may take a variety of forms, such as, for example, magnetic or electric sensors, and may communicate in real-time. Illustrative magnetic sensors may include coil windings and solenoid windings that utilize induction phenomenon to sense conductivity of the earth formations. Illustrative electric sensors may include electrodes, linear wire antennas or toroidal antennas that utilize Ohm's law to perform the measurement. In addition, the sensors may be realizations of dipoles with an azimuthal moment direction and directionality, such as tilted coil antennas. In addition, the sensors may be adapted to perform sensing (e.g., logging) operations in the up-hole or downhole directions.
The various embodiments and method described herein may be utilized used for any application that requires temporary or permanent coil/toroid and receiver deployment inside or outside the casing. Such applications include, for example, production fluid analysis, waterflood monitoring in enhanced oil recovery environments, monitoring borehole cement, monitoring casing integrity, monitoring the operational condition of sliding sleeves, telemetry, etc. Since the sensor arrays are pre-manufactured, they may be readily reeled onto a spool and deployed in a fast and efficient manner at the well site, thus significantly reducing rig time and the associated costs.
Embodiments and methods of the present disclosure described herein further relate to any one or more of the following paragraphs:
1. A reelable sensor array, comprising a plurality of sensors coupled one to another via a cable to form a reelable sensor array, wherein the reelable sensor array is adapted to be reeled onto a spool, unreeled from the spool, and attached to a tubular.
2. A reelable sensor array as defined in paragraph 1, further comprising a plurality of flexible backings, wherein each flexible backing has a plurality of sensors thereon.
3. A reelable sensor array as defined in paragraphs 1 or 2, wherein the sensors are oriented on the flexible backings such that their axes are parallel to an axis of the tubular.
4. A reelable sensor array as defined in any of paragraphs 1-3, wherein the sensors are oriented on the flexible backings such that their axes are transverse to an axis of the tubular.
5. A reelable sensor array as defined in any of paragraphs 1-4, wherein the sensors on the flexible backings are coupled to one another in series.
6. A reelable sensor array as defined in any of paragraphs 1-5, wherein the sensors on the flexible backings are azimuthally separated into directionally sensitive groups.
7. A reelable sensor array as defined in any of paragraphs 1-6, wherein the sensors are transmitters or receivers.
8. A reelable sensor array as defined in any of paragraphs 1-7, wherein the sensors are coils, toroids, galvanic electrodes, capacitive electrodes, or fiber optic sensors.
9. A reelable sensor array as defined in any of paragraphs 1-8, wherein the cable is at least one of a power, data communication, or fiber optic cable.
10. A reelable sensor array as defined in any of paragraphs 1-9, wherein the flexible backing comprises an adhesive on a side opposite a side on which the sensors are positioned.
11. A reelable sensor array as defined in any of paragraphs 1-10, wherein the flexible backing comprises a connector to connect opposite ends of the flexible backing.
12. A reelable sensor array as defined in any of paragraphs 1-11, wherein the flexible backing further comprises pockets into which the sensors are positioned.
13. A method for deploying reelable sensors into a downhole wellbore, the method comprising unreeling a sensor array from a spool, the sensor array comprising a plurality of sensors communicably coupled one to another via a cable; attaching the sensor array to a tubular; and deploying the tubular downhole into a wellbore.
14. A method as defined in paragraph 13, wherein the plurality of sensors are used as transmitters or receivers.
15. A method as defined in paragraphs 13 or 14, wherein the sensor array is attached to the tubular as the tubular is being deployed into the wellbore.
16. A method as defined in any of paragraphs 13-15, wherein attaching the sensor array to the tubular comprises clamping the sensor array to the tubular.
17. A method as defined in any of paragraphs 13-16, wherein the sensor array comprises a plurality of flexible backings, each flexible backing having a plurality of sensors attached thereto; and attaching the sensor array to the tubular comprises wrapping the flexible backings around the tubular.
18. A method as defined in any of paragraphs 13-17, wherein attaching the sensor array further comprises securing the flexible backing around the tubular using connectors forming part of the flexible backing.
19. A method as defined in any of paragraphs 13-18, wherein attaching the sensor array further comprises securing the flexible backing around the tubular using adhesive.
20. A method as defined in any of paragraphs 13-19, wherein attaching the sensor array further comprises clamping the cable to the tubular.
21. A method as defined in any of paragraphs 13-20, further comprising exciting each sensor on a flexible backing in-series.
22. A method as defined in any of paragraphs 13-21, further comprising exciting each sensor on a flexible backing azimuthally.
23. A method as defined in any of paragraphs 13-22, wherein the tubular is deployed as a drilling, casing, or production string.
24. A method of assembling a downhole reelable sensor array, the method comprising fabricating a plurality of sensors; communicably coupling the sensors using a cable, thereby forming a reelable sensor array; and reeling the sensor array onto a spool.
25. A method as defined in paragraph 24, further comprising positioning the spool near a wellbore; unreeling the sensor array from the spool; attaching the sensor array to a tubular; and deploying the tubular downhole into the wellbore.
26. A method as defined in paragraphs 24 or 25, wherein the sensors are fabricated as a plurality of flexible backings having sensors thereon.
27. A method as defined in any of paragraphs 24-26, wherein reeling the sensor array onto the spool comprises wrapping the flexible backings around a rigid body; and reeling the sensor array onto a spool.
28. A method as defined in any of paragraphs 24-27, wherein attaching the sensor array to the tubular comprises wrapping the flexible backings around the tubular.
29. A method as defined in any of paragraphs 24-28, wherein attaching the sensor array to the tubular comprises clamping the sensor array to the tubular.
30. A method as defined in any of paragraphs 24-29, wherein attaching the sensor array to the tubular comprises clamping securing the flexible backing array to the tubular using adhesive.
31. A method as defined in any of paragraphs 24-30, wherein the tubular is deployed downhole as a drilling, casing or production string.
Although various embodiments and methods have been shown and described, the disclosure is not limited to such embodiments and methodologies and will be understood to include all modifications and variations as would be apparent to one skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/012587 | 1/8/2016 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2017/119896 | 7/13/2017 | WO | A |
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Entry |
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International Search Report and the Written Opinion of the International Search Authority, or the Declaration, dated Sep. 12, 2016, PCT/US2016/012587, 18 pages, ISA/KR. |
Number | Date | Country | |
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20180066509 A1 | Mar 2018 | US |