Patent Application
20110083856
Sensors and other gauges are deployed into and exposed to the environment within a wellbore to measure wellbore properties such as temperature and pressure. A typical environment within a wellbore can include drilling fluids, injections fluids, finishing fluids, hydrocarbons, acids, debris, and gases. As such, the environment in the wellbore can be corrosive. Continuous exposure to corrosive environments can cause premature failure of the sensors and other gauges, which causes unplanned use of a workover rig to remove and replace. The unplanned use of workover rigs increases rig time, costs, personnel costs, and production delays. Each unplanned use of a workover rig also increases operational risks to both equipment and personnel.
There is a need, therefore, for new apparatus and methods for selectively deploying one or more sensors into a wellbore and retrieving the sensors therefrom without the use of a workover rig or similar technology. There is also a need for new apparatus and methods for selectively exposing the sensors to the wellbore environment without the use of a workover rig or similar technology.
Apparatus, systems, and methods for deploying a sensor and selectively retrieving the sensor are provided. In at least one specific embodiment, the apparatus includes an outer tubular member disposed about one or more inner tubular members. Each tubular terminates within a fluid directional controller that comprises a housing disposed about the tubular members. At least one opening is formed through the housing, and provides fluid communication between an interior cavity thereof of the housing and an exterior thereof. A flow control device is disposed within the housing between the tubular members and the opening. The flow control device can be selectively actuated to expose the interior cavity of the housing to an external environment.
In at least one other specific embodiment, a bi-directional flow apparatus can be disposed into a wellbore. The bi-directional flow apparatus can include an outer tubular member disposed about one or more inner tubular members. In addition, at least one sensor can be disposed within at least one of the tubular. A fluid directional controller can be secured to at least one of the tubular members containing the sensor. A fluid can be used to flow the sensor in a first direction through the tubular housing the sensor. The sensor can be located within the fluid directional controller, and exposed to an environment of the wellbore for measuring or sensing.
In at least one other specific embodiment, the system includes a completion assembly having an inner bore and a bi-directional flow apparatus connected to the completion assembly. The bi-directional flow apparatus can include an outer tubular member disposed about one or more inner tubular members. Each tubular terminates within a fluid directional controller that comprises a housing disposed about the tubular members. The housing can include at least one opening formed there through and in fluid communication with an interior cavity of the housing and an exterior of the housing. A flow control device can be disposed within the housing between the tubular members and the opening. The flow control device can be selectively actuated to expose the interior cavity to an external environment.
So that the recited features can be understood in detail, a more particular description, briefly summarized above, may be had by reference to one or more embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
The tubular members 110, 120, 130 can be one or more segments or sections of pipe, coiled tubing, or other tubular members. When two or more segments are used, each segment or section of tubular members can be coupled together such that flow between the segments of the tubular members is unobstructed. For example, the segments can be coupled together by one or more mechanical fasteners, welds, solders, pressure fits, adhesives, threaded connections, snap latches, or other similar fasteners so that flow between the segments is unobstructed. Preferably, the segments are coupled together by a conduit splice (not shown in
The sensors 150 can be any downhole sensing or measuring device. Illustrative sensors 150 can include, both single point and distributed measurements for example, one or more pressure sensors, temperature sensors, fluid type analyzers, pH sensors, distributed temperature, distributed pressure, distributed vibration, and acoustic measurements, among others. The sensors 150 can be deployed with or without communication or control lines 152. The communication line 152, for example, can be or include one or more fiber optic lines, electrical lines, and/or other communication lines. The communication line 152 can provide communication and/or power between the sensors 150 and one or more remote signal sources, transmitters, and/or processors.
The apparatus 100 can protect the sensors 150 and communication lines 152, if needed, from corrosive environments, liquids, and/or gases within the wellbore 105 or other environment to be monitored. In operation, one or more sensors and one or more optional communication lines 152 can be disposed within any one of the inner tubular members 120, 130 or the annulus 140, and the apparatus 100 can be at least partially disposed within or adjacent the wellbore 105 or other environment to be monitored. Fluid flow can be initiated through the tubular 120, 130 or annulus 140 that is housing the sensor 150 to be deployed. A return or circulation flow path will then be established through the one or more available tubulars 120, 130 or annulus 140 that are not housing the sensor 150 to be deployed.
For example, one or more sensors 150 and optional communication lines 152 can be disposed within the first inner tubular member 120 and pressurized with fluid such that the fluid can flow through the tubular member 120 in the first or deployment direction 160. The fluid can return through the flow path of the annulus 140 in a reverse direction, i.e., a second or retrieval direction 170. The second inner tubular member 120 can remain idle or be used as a secondary flow path for either the first 160 or second directions 170. The first direction 160 can be into or toward the wellbore 105 and the second direction 170 can be from or out of the wellbore 105. In another example, fluid can flow through the annulus 140 in the first direction 160, and can return through one or both of the second tubular members 120,130 in the second direction 170. If only one of the second tubular members 120,130 is needed for deployment the other can remain idle or serve as the retrieval flow path. The idle flow paths can be used to flow a purging fluid or other material to expel or prevent unwanted liquid and/or gas within the apparatus 100.
The coupling 215 can include one or more openings or flow paths (three are shown 217, 219, 225) formed therethrough. The deployment and retrieval apparatus 100 can be secured to the coupling 215. For example, the coupling 215 can be secured to the outer diameter of the first tubular member 110, and second tubular members 120, 130 can be aligned with the openings or flow paths 217, 219 of the coupling 215 to allow fluid communication through the tubular members 120, 130 into the interior cavity 220 of the housing 210. The first tubular member 110 can also be aligned with the coupling 215 to allow fluid communication between the annulus 140 within the first tubular member 110 and the interior cavity 220 of the housing 210 via the opening or flow path 225.
The flow control device 240 can be any device capable of regulating flow. The flow control device 240 can be selectively actuated electronically, mechanically, hydraulically, or by other remote actuation methods. In at least one specific embodiment, the control device 240 can be a ball and seat type flow control valve or check valve, as depicted in
Referring to
In operation, the deployment and retrieval apparatus 100 can be secured to the coupling 215 to establish fluid communication between the first inner tubular 120 and flow path 217, and between the second inner tubular 130 and the flow path 219. Additionally, the annulus 140 within the outer tubular member 110 is in fluid communication with the flow paths 225. As mentioned above, the one or more sensors and optional one or more communication lines 152 can be disposed within any one of the inner tubular members 120, 130 or the annulus 140. As depicted in
When the flow control device 240 is opened, the inner cavity 220 of the fluid direction controller 200 can be exposed to the surrounding environment within the wellbore 205, allowing the fluid from the surrounding environment to contact the sensor 150. The fluid from the surrounding environment can enter the inner cavity 220 of the housing 210 by flowing through the apertures 230. The apertures 230 can be formed through one or more surfaces or sides of the housing 210. The environmental fluid can then flow through the flow path 241 within the flow control device 240 when the ball 248 is in the second or open position. Once the sensor 150 performs its measurements or readings on the fluid from the surrounding environment, the ball 248 can be returned to the closed position by releasing the pressure in the tubular 130. If desired, a purging fluid can be conveyed through the apparatus 100 through any one or more of the tubulars 110, 120, 130, annulus 140, or any combination thereof, to clean out the cavity 220 provided within the housings 215. As such, the sensor 150 and/or communication line 152 can have limited exposure to the surrounding fluid for a predetermined and/or controllable period of time.
After a period of time, the sensor 150 may need to be replaced or substituted with a second sensor (not shown). For example, a second sensor may be needed to take a different measurement or reading. Although not shown in
For example, the three-way flow control device 320 can have a first mode that provides fluid communication between the second tubular members 120, 130. A second mode can be selected that provides fluid communication between the second tubular member 120, the first tubular member 110, and the wellbore 305. Further, in some cases a third mode can be configured that provides fluid communication between the second tubular member 130, the first tubular member 110, and the wellbore 305. Additionally, in other cases a fourth mode can be chosen that provides fluid communication between the second tubular members 120, 130, the first tubular member 110, and the wellbore 305. In at least one specific embodiment, the three-way flow control device 320 can be a three-way pressure relief valve that can be switched between the modes by changing the pressure within the wellbore 305, within the second tubular member 120, and/or within the third tubular member 130.
In one or more embodiments, the three-way flow control device 320 can be another valve or flow control device, such as a mechanically, a hydraulically, or an electrically operated valve, and the three-way flow control device 320 can be remotely switched between modes. For example, the three-way flow control device 320 can be switched between modes by a signal sent from the surface to a solenoid adjacent the three-way flow control device 320. The signal can be transmitted or communicated to the solenoid by wireless telemetry equipment, such as electromagnetic waves, acoustic waves, or the like, or by wire type telemetry, such as a fiber optic cable or an electrical wire. The three-way flow control device 320 can be configured to be switched between the various modes by any hydraulic, mechanical, or electrical means.
The three-way flow control device 320 can be selectively switched between modes to expose the sensor 150, which can be disposed within the second tubular member 120 adjacent the return conduit 310, to one or more conditions of the wellbore 305. For example, the three-way flow control device 320 can be placed in the second mode to provide a flow path between the wellbore 305 and the second tubular member 120.
Furthermore, the three-way flow control device 320 can be placed in the first mode to provide a flow path between the tubular members 120, 130 to enable deployment of the sensor 150 and/or communication line 152. Such a configuration would enable circulation of the fluid used to deploy the sensor 150 and/or communication line 152. For example, the sensor 150 can be located within the second tubular member 120 and fluid within the second tubular member 120 can flow in a first direction 160 from the surface. Accordingly, the fluid could deploy the sensor 150. Additionally, the fluid can flow through the three-way flow control device 320 to the return conduit 310 and to the third tubular member 130. Within the third tubular member 130 the fluid would flow in a second direction 170 towards the surface, counter to the first direction 160, and thereby complete a circular cycle.
The sensor 150 can be retrieved from the wellbore 305 by reversing the direction of flow in the tubular member 120. For example, in one situation the three-way flow control device 320 can be placed in the first mode establishing a fluid pathway between the third tubular member 130 and the return conduit 310. This would enable fluid within the third tubular member 130 to flow in the first direction 160 and continue through the three-way flow control device 320 and the return conduit 310 to the second tubular member 120. The fluid within the second tubular member 120 can then return to the surface by flowing in the second direction 170. The force or motion of the fluid flowing within the second tubular member 120 can facilitate the movement of the sensor 150 disposed within the second tubular member 120 to the surface. In one or more embodiments, the fluid directional controller 300 can enable one or more sensors 150 and/or communication line 152 to be deployed into the wellbore 305 and one or more sensors 150 to be retrieved from the wellbore 305 simultaneously.
In some embodiments, a fluid 307, such as a chemical injection for example, can flow through the inner diameter of the tubular member 110 and provide a desired treatment and/or additives to the wellbore 305. The addition of the fluid 307 can be done independently of the deployment or retrieval of one or more sensors 150 and/or communication lines 150.
The fluid directional controller 300 can be connected to or include a blow out preventer 340 or safety valve, for example. Via a control line 345 or a remotely initiated signal the blow out preventer 340 can be used to form a pressure seal either around the sensor or with no sensor in place. This allows an embodiment of a system using the fluid directional controller 300 to pump the sensor 150 into place and then seal around the sensor 150 using the blow out preventer 340. The three-way flow control device 320 can then be used to establish fluid communication between the sensor 150 and the surrounding wellbore 305, enabling the sensor 150 to detect the surrounding wellbore conditions. By using the blow out preventer 340 and the three-way flow control device 320 in this way, the wellbore fluid may be isolated to just the sensor 150 and return conduit 310, thereby avoiding the potential of having wellbore fluids travel up either of the tubulars to the surface.
The apparatus 100 can deploy the sensor 150 adjacent, into, or about the completion assembly 402. The apparatus 100 can be deployed free hanging from the surface of the wellbore 405 or the apparatus can be secured to the wellhead 440. In one or more embodiments, the apparatus 100 can be integrated with the completion assembly 402, disposed within the completion assembly 402, disposed behind the completion assembly 402, and/or disposed about a portion of the completion assembly 402.
The packers 480 can be any one or more compression or cup packers, inflatable packers, “control line bypass” packers, retrievable type, permanent type, or any other type known in the art. Preferably, the packers 480 are selectively actuated or set within the wellbore 405 to isolate two or more portions of the wellbore 405 from one another.
The tubing hanger 450 can be any one or more inflatable tubing hangers, mudline tubing hangers, pack-off tubing hangers, or any other type known in the art. A preferred tubing hanger is described in U.S. Pat. No. 7,422,065, the contents of which are incorporated herein by reference. The tubing hanger 450 can seal a portion of the wellbore 405, and support the tubing string 490.
The wellbore 405 can be cased, as depicted, with casing 408, or the wellbore 405 can be left as an open hole. When the wellbore 405 is cased, the casing 408 can have one or more perforations 495 formed therein. The perforations 495 can be formed adjacent a hydrocarbon bearing zone 497, or similar reservoir of interest. After the perforations 495 are formed through the casing 408, the tubing string 490 and the apparatus 100 can be conveyed into the wellbore 405. When the tubing string 490 is located within the wellbore 405, a perforated or slotted portion 492 of the tubing string 490 can be located proximate to the perforations 495, and an end of the inner bore of the tubing string 490 adjacent the perforation portion 492 can be isolated from the wellbore 405 by a sealing member 498. In addition or alternatively, an inflow control device (not shown) may be used to allow fluid from the reservoir to flow into the production tubing string 490.
Accordingly, the perforated portion of the tubing string 490 can be selectively used to produce hydrocarbons or other desired fluids from the hydrocarbon bearing zone 497. In addition or alternatively, the tubing string 490 can also provide fluid (e.g., injection, treatment, steam, or other) to the wellbore 405 and/or the hydrocarbon bearing zone 497 adjacent the perforations 495. The hanger 450 and the packer 480 can be actuated after the tubing string 490 is located within the wellbore 405. The apparatus 100 and tubing string 490 can be secured within the wellbore 405 when the hanger 450 and packer 480 are actuated. Furthermore, the hanger 450 and the packer 480 can seal an annulus between the tubing string 490 and the casing 408.
In one or more embodiments, the apparatus 100 can include one or more sections (two are shown 410, 420) coupled together by a conduit splice 415. The conduit splice 415 can provide flow paths placing the first segment 410 in fluid communication with the second segment 420. Accordingly, the conduit splice 415 allows for deployment of a communication line 152 that is continuous, circulation of fluids between the segments 410, 420, and uninterrupted deployment of the sensor 150.
After the tubing string 490 and the apparatus 100 are secured within the wellbore 405, the first segment 410 and the tubing string 490 can be connected to the wellhead 440. The wellhead 440 can be connected to the wellhead outlet 430, and the wellhead outlet 430 can be placed in fluid communication and/or connected with the apparatus 100. The wellhead outlet 430 can also be in communication with the junction box 435, which can be configured to provide power to the sensor 150 and/or the completion assembly 402. In addition, the junction box 435 can also send signals to and/or receive signals from the sensor 150.
The wellhead outlet 430 can be used to provide fluid flow for the tubing string 490 and the apparatus 100. The fluid flowing in the apparatus 100 can be used to deploy the sensor 150. The sensor 150 can flow through the segments 410, 420 into a fluid directional controller 465. For example, the wellhead outlet 430 can provide fluid flow to the apparatus 100, and the sensor 150 can be deployed through the first segment 410. The sensor 150 can flow from the first segment 410 to the second segment 420 via conduit splice 415. The second segment 420 can be connected to the fluid directional controller 465 and the sensor 150 can be disposed therein.
The embodiment of the fluid directional controller 465 can be any manifold or other device that enables bi-directional flow through the apparatus 100 and selectively exposes the sensor 150 to the wellbore 405. For example, the fluid directional controller 465 can be similar to any of the fluid directional controllers described herein. The sensor 150 can flow from the second segment 420 into the fluid direction controller 465, and the fluid directional controller 465 can be used to selectively expose the sensor 150 to the environmental conditions of the wellbore 405. To retrieve the sensor 150 from the wellbore 405, the wellhead outlet 430 can be used to provide a reverse flow through the apparatus 100, as previously described herein.
The secondary housings 540, 550 can be disposed within the main housing 530. The secondary housings 540, 550 can be configured to respectively couple together the second tubular members 120, 130 of one segment 510 with the second tubular members 120, 130 of the other segment 520. As such, the conduit splice 500 respectively establishes flow paths 542, 552 between the tubular members 120, 130 of the segments 510, 520. Accordingly, the conduit splice 500 facilitates bi-directional flow through at least two of the tubular members 110, 120, 130 of segments 510, 520.
The fluid can flow in a first direction 160 within at least one of the tubular members 110, 120, 130 of the segments 510, 520, and flow in a second direction 170 within another of the tubular members 110, 120, 130. For example, the fluid flowing in the first direction 160 within the tubular members 110,120, 130 can deploy one or more sensors 150 and/or communication lines 152 into the wellbore 505. The communications line 152 can be continuously deployed through the wellbore 505. Flowing the fluid in the direction opposite to 160 (i.e., the second direction 170) can retrieve one or more previously deployed sensors 150 and communication lines 152 from the wellbore 505. During the deployment and retrieval of sensors 150 and communication lines 152, the flow paths 502, 542, and 552 can provide fluid communication and uninterrupted flow between the segments 510, 520.
The first clamp 620 can be configured to engage and seal about the outer diameter of the first tubular member 110 of the apparatus 100. The passageways 630, 640 present in the interface housing 610 can be configured to have the tubular members 120, 130 respectively disposed there through. The passageways 630, 640 can be provided in the interface housing 610 such that the tubular members 120, 130 are operatively aligned with the first tubular member 110. In addition, the passageways 630, 640 can be configured to respectively seal with the outer diameters of the tubular members 120, 130.
The passageway 650 can provide another orifice for the input and exit of fluid. Accordingly, fluid can be introduced into the annulus of first tubular member 110 via a conduit 655 attached to a fluid source. Alternatively, fluid can exit the annulus of the first tubular member 110 via an interior cavity of the interface housing 610 by flowing through the passageway 650. The passageway 650 can have one or more conduits 655 at least partially disposed therethrough. In some embodiments, the conduit 655 can be a nozzle, a valve, or a tube, or a combination of the components. In one or more embodiments, the flow of fluid into or out of the interface housing 610 can be selectively controlled by the conduit 655.
The wellhead 600 can also facilitate the circulation of fluids within the apparatus 100. For example, the wellhead 600 can allow the introduction of fluid pumped in a first direction 160 within the tubular member 120. The fluid may then circulate and return or exit in a second direction 170 within the first tubular member 110. The fluid may continue to exit in the second direction 170 out of the wellhead 600 via the passageway 650. In one or more embodiments, the conduit 655 can be in fluid communication with a recycle loop allowing the fluid exiting the passageway 650 to be returned to the apparatus 100, for example through the tubular member 120. Of course, the reverse of the cycle may be used for retrieving a sensor previously deployed in the tubular member 120. Although not depicted, it is understood to those of ordinary skill in the art that such a wellhead outlet could also include additional pressure isolation barriers incorporated to meet associated health and safety requirements.
Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
