Patent Grant
7346455
The present invention relates to equipment and techniques to evaluate wellbore conditions. More particularly, the invention relates to improved techniques to evaluate wear and corrosion of one or more strings in a production wellbore having a downhole pump driven by a sucker rod powered at the surface.
Oil and gas wells are typically drilled with a rotary drill bit, and the resulting borehole is cased with steel casing cemented in the borehole to support pressure from the surrounding formation. Hydrocarbons may then be produced through smaller diameter production tubing suspended within the casing. Although fluids can be produced from the well using internal pressure within a producing zone, pumping systems are commonly used to lift fluid from the producing zone in the well to the surface of the earth. This is often the case with mature producing fields where production has declined and operating margins are thin.
The most common pumping system used in the oil industry is the sucker rod pumping system. A pump is positioned downhole, and a drive motor transmits power to the pump from the surface with a sucker rod string positioned within the production tubing. Rod strings include both “reciprocating” types, which are axially stroked, and “rotating” types, which rotate to power progressing cavity type pumps. The latter type is increasingly used, particularly in wells producing heavy, sand-laden oil or producing fluids with high water/oil ratios. The rod string can consist of a group of connected, essentially rigid, steel or fiberglass sucker rod sections or “joints” in lengths of 25 or 30 feet. Joints are sequentially connected or disconnected as the string is inserted or removed from the borehole, respectively. Alternatively a continuous sucker rod (COROD) string can be used to connect the drive mechanism to the pump positioned within the borehole.
A number of factors conspire to wear down and eventually cause failure in both sucker rods and the production tubing in which they move. Produced fluid is often corrosive, attacking the sucker rod surface and causing pitting that may lead to loss of cross-sectional area or fatigue cracking and subsequent rod failure. Produced fluid can also act like an abrasive slurry that can lead to mechanical failure of the rod and tubing. The rod and tubing also wear against each other. Such wear may be exacerbated where the well or borehole is deviated from true vertical. Even boreholes believed to have been drilled so as to be truly vertical and considered to be nominally straight may deviate considerably from true vertical, due to factors such as drill bit rotational speed, weight on the drill bit, inherent imperfections in the size, shape, and assembly of drill string components and naturally-occurring changes in the formation of the earth that affect drilling penetration rate and direction. Also, some boreholes are intentionally drilled at varying angles using directional drilling techniques designed to reach different parts of a hydrocarbon-producing formation. As a result, sucker rods and production tubing are never truly concentric, especially during the dynamics of pumping, and instead contact one another and wear unpredictably over several thousand feet of depth. Induced wear is therefore a function of many variables, including well deviation from true vertical; angle or “dogleg” severity; downhole pump operating parameters; dynamic compression, tensile and sidewall loads; harmonics within the producing sucker rod string; produced solids; produced fluid lubricity; and water to oil ratio. Additionally, in certain conditions, such as in geologically active areas or in areas of hydrocarbon production from diatomite formations, wellbores may shift over time, causing additional deviation from vertical.
Boreholes deviate considerably from true vertical due to various factors, including drill bit rotational speed, weight on the drill bit, inherent imperfections in the size, shape, and assembly of drill string components and naturally-occurring changes in the formation of the earth. When using a tubing anchor to rigidly fix the lower part of a tubing string in a wellbore relative to the casing, it is often necessary to apply a tensile load to the tubing string to prevent sags or kinks in the tubing in certain zones of the wellbore. In certain conditions, such as in geologically active areas or in areas of hydrocarbon production from diatomite formations, producing wells may shift over time, causing additional deviation from vertical. As a result, sucker rods and production tubing are often never truly concentric, especially during the dynamics of pumping, and instead contact one another and wear in certain areas, some of which are known as “doglegs”, or where the tubing sags or is kinked. Without a continuous deviation survey of the wellbore, it is difficult, if not impossible, to identify areas where the well deviation from vertical results in contact and wear of the rods and tubing.
For many years it has been possible to determine the deviation of a borehole, or wellbore, from true vertical. Such techniques are used extensively in the drilling of new wellbores, either as periodic “single shot” surveys, “multishot” surveys or even continuously while drilling, known as “MWD”. U.S. Pat. No. 6,453,239 to Shirasaka, et al, U.S. Pat. No. 5,821,414 to Noy, et al, U.S. Pat. No. 4,987,684 to Andreas, et al and U.S. Pat. No. 3,753,296 to Van Steenwyk, disclose such examples of surveying wellbores. However, in the case of most existing rod-pumped oil wells, any such surveys performed during the original drilling of the well largely comprised periodic surveys of wellbore direction and inclination performed only at one or two key intervals during the well-drilling operation. Consequently, a continuous profile of the wellbore deviation, giving rise to tubing and rod wear, is not generally known. Alternatively, performing a dedicated, continuous directional survey of existing wellbores, such as those contemplated in the above patents, is generally cost-prohibitive. There is a need for a cost-effective directional survey that can be integrated into well work-over operations of existing producing wellbores to obtain an accurate, nearly continuous deviation profile and allow mitigation of rod and tubing wear.
Prior art wellbore deviation techniques and tools are generally designed for the measurement of a wellbore while drilling, or are used on wireline or slickline during the process of drilling, to measure the direction and inclination of the wellbore with respect to an as-yet un-reached planned trajectory or target of interest. Prior art accelerometer and magnetometer deviation tools are also typically capable of determining wellbore inclination and azimuth only outside of the presence of magnetic interference, e.g., in open, uncased wellbores.
Oil well production string inspection methods conventionally use magnetic flux leakage techniques and typically rely only upon signal amplitude and time-based denominations or, in some cases, signal amplitude and wellbore depth, to provide the equipment operator with information representing the sucker rod or tubing string condition. U.S. Pat. Nos. 2,555,853, 2,855,564, 4,492,115, 4,636,727, 4,715,442, 4,843,317, 5,914,596, 6,316,937 disclose methods and apparatus to perform magnetic flux leakage inspections of sucker rods and tubing as elements of the production wellbore.
The amplitude of a magnetic flux leakage signal from a flaw in a ferromagnetic material under test is a function of many variables, including magnetic permeability of the material under test; magnetizing field strength; detection sensor type; sensor-to-material-under-inspection stand-off; flaw orientation relative to magnetic field direction; flaw volume; flaw depth, flaw shape; sensor-to-material-under-inspection relative velocity; sensor signal filtering and; sensor signal-to-noise ratio, among others. Conventional systems that rely only upon amplitude and time, or upon amplitude and wellbore depth, are susceptible to misinterpretation since the apparent flaw signal amplitude may be a function of many factors other than depth alone. Many such systems do not employ field standardization techniques to establish flaw standardization levels for inspection. Even those methods that do employ standardization techniques rely upon signal amplitude alone for flaw severity analysis.
Some prior art gyroscope and accelerometer deviation tools, of either the gimballed or strapped-down type, are capable of use inside cased hole and are generally used during the drilling process. U.S. Pat. No. 4,468,863 discloses a single shot or periodic multi-shot survey tool deployed on a wireline. U.S. Pat. No. 5,821,414 discloses a system for measuring deviation and inclination, while a wellbore is being drilled, to achieve an ultimate bottom hole location that positions the wellbore to optimally drain the target hydrocarbon reservoir. Most Measurement-While-Drilling applications that are intended for open hole, high temperature, high pressure environments, as disclosed in U.S. Pat. No. 6,714,870 to Weston, et al. Such tools are typically large, insulated, shock-absorbing, high pressure- and temperature-resistant to handle the extremely demanding environment of drilling in extreme temperature, vibration and pressure, as disclosed in U.S. Pat. No. 4,302,886. Systems may utilize relatively gimbaled gyroscopes or expensive and complex Coriolis-effect strapped-down gyroscopes, as disclosed in U.S. Pat. No. 6,453,239. Such tools are generally too large and lengthy to be used inside small diameter production tubing, and too expensive for most pumped well application. The high cost of these systems prohibits consideration by the operators of relatively shallow, existing rod-pumped, producing wells in the declining fields of mature sedimentary basins.
Failure of pumped oil wells due to the cumulative effect of the wear of sucker rods on tubing and such wear combined with corrosion is considered to be the single largest cause of well down time. Generally accepted methods of mitigating such wear include installing rod guides to centralize the sucker rod in the tubing with selected tubing surface contact materials; sinker bars to add weight to the sucker rod string; tubing insert liners composed of wear-resistant materials such as nylon and polythene; and improving operational practice. Examples of rod guides are disclosed in U.S. Pat. No. 6,152,223 to Abdo, U.S. Pat. No. 5,339,896 to Hart, U.S. Pat. No. 5,115,863 to Olinger, and U.S. Pat. Nos. 5,492,174 and 5,487,426 to O'Hair. An example of a tubing liner insert is U.S. Pat. No. 5,511,619 to Jackson. Since many of these mitigation techniques are expensive to apply, oil well operators must carefully assess the economics of any such mitigation techniques.
Although wear can be mitigated, it cannot be eliminated, so inspection of sucker rods and production tubing are common in the industry. Well operators within the industry commonly follow a “run until failure” approach, only inspecting components upon failure of some element of the wellbore, which may include a hole or split in the tubing, pump failure, rod failure, or tubing separation. The nature of the industry is that down-time is costly, both in terms of lost or deferred production and the actual cost to repair the failure by work-over of the wellbore. Another reason well operators are reluctant to perform inspections at regular intervals is that the diagnostic capabilities of current inspection practices are somewhat limited. A more useful, reliable, and economical method of wear and corrosion pattern analysis and diagnosis that gives rise to mitigation opportunities would allow operators to be more proactive. Further, many operators are unable to devote the time and human resources to perform the necessary analysis of data such as well deviation, rod failure and tubing failure.
The most basic wear analysis techniques include simply observing the wear patterns contained within the individual lengths of oil well production tubing, to empirically inspect tubing for wall thickness loss due to mechanical wear and corrosion of sucker rods and tubing. Caliper surveys are available to measure the inside diameter of production tubing but cannot examine the condition of the outside condition of the tubing.
More sophisticated inspection techniques employ magnetic sensor technologies to assess the condition of production tubing. Magnetic testing devices have been known for many years, as disclosed in U.S. Pat. No. 2,555,853 to Irwin and more specifically for oilfield tubulars and sucker rods in U.S. Pat. No. 2,855,564 to Irwin for a Magnetic Testing Apparatus and Method. Applying this technology to the inspection of oilfield tubulars, U.S. Pat. Nos. 4,492,115, 4,636,727 and 4,715,442 disclose tubing trip tools and methods for determining the extent of defects in continuous production tubing strings during removal from the well. The tools and methods include magnetic flux leakage sensor coils and Hall effect devices for detecting defects such as average wall thickness, corrosion, pitting, and wear. One or more of the above tools further include a velocity and position detector for correlating the location of individual defects to their locations along the tubing string. A profile of the position of the defects in the continuous string can also be established.
U.S. Pat. No. 4,843,317 to Dew discloses a method and apparatus for measuring casing wall thickness using an axial main coil for generating a flux field enveloping the casing wall. U.S. Pat. No. 6,316,937 to Edens discloses a combination of magnetic Hall effect sensors and digital signal processing to evaluate defects and wear. U.S. Pat. No. 5,914,596 to Weinbaum discloses a magnetic flux leakage and sensor system to inspect for defects and measure the wall thickness and diameter of continuous coiled tubing. All of these systems induce magnetic flux within the tubing. Surface defects result in magnetic flux leakage. Sensors measure the leakage and are thereby used to locate and quantify the surface defect.
Techniques are also known for magnetically inspecting sucker rods. Conventional sucker rod segments are commonly removed from an oil well, separated, and trucked to inspection plants to be “reclaimed”. U.S. Pat. No. 2,855,564 to Irwin discloses a magnetic testing apparatus used in inspection of sucker rods, and U.S. Pat. No. 3,958,049 to Payne discloses an example of a process for reclaiming used sucker rod. In the latter patent, the salvaged rod is degreased, visually inspected, subjected to a shot peening operation, and analyzed for structural imperfections. Magnetic induction techniques are employed, albeit at an inspection plant, rather than on-site. A system for evaluating a coiled sucker rod string, or “COROD”, as it is pulled from a well is disclosed in U.S. Pat. No. 6,580,268. Defects within the COROD may be correlated with their position. The system generates “real time” calculated dimensional display of the COROD and cross-sectional area as a function of position. Wireless technology can be used, such as to convey signals from a processor unit as many as 200 feet to a laptop server.
Aspects of the sucker rod and production tubing inspection techniques discussed above have a certain level of sophistication, such as the use of wireless technology and digital signal processing. Ironically, however, the analyses derived from the resulting data are relatively limited and shortsighted. The data obtained is not optimally used to correct or mitigate wear. For example, the end result of conventional sucker rod inspection and reclamation is the rather simplistic determination of whether to re-classify and reuse or dispose of each rod.
Additionally, because the production tubing in most rod-pumped producing wells is tubing that has previously been used in other wells or from such reclaimed supplies, pre-existing wear patterns on tubing alone are often misleading as to the root causes of tubing wear in the current wellbore. Further, even a detailed, positional analysis of defects does not provide an adequate window as to their root cause or mitigation. For example, in general, well operators simply reposition rod guides, which may merely shift wear on the rod or tubing to another position along the string. An alternative technique to mitigate rod wear on tubing is disclosed in U.S. Pat. No. 36,362E to Jackson, whereby an abrasion resistant polymer, such as polyethylene, is inserted into the tubing. This technique, however, reduces the inside diameter of the tubing and does not assess the cause of tubing wear. As a result, the polythene liner may simply fail over time, rather than the tubing, which still necessitates work-over. Not even “real time” data reports provide an adequate solution to mitigating wear, because they do nothing to improve the quality or scope of the analysis, or correlate tubing condition information with rod condition information. An accurate analysis of the cause of wellbore failure due to tubing or rod failure is also aided with a profile of the wellbore deviation.
Another problem with existing inspection systems is that there is no available means of performing these assessments in a cost-effective and timely manner so that tubing wear can be mitigated through an economical solution specific to a well. Because quickly returning the well to production is of paramount importance, full analysis of any limited information available is often difficult, if not impossible, to perform before the well is returned to production.
The disadvantages of the prior art are overcome by the present invention. An improved system is provided for evaluating and mitigating one or more of wear and corrosion on rod strings and/or tubular strings while being pulled from a wellbore.
A wellbore evaluation system and method are provided for evaluating one or more of wear and corrosion to certain critical components of a well system. The well system includes a production tubing string positionable in a well and a sucker rod string movable within the production tubing string. In one embodiment, two or more sensors are selected from the group consisting of a deviation sensor movable within the well to determine a deviation profile; a rod sensor for sensing and measuring wear, corrosion pitting, cross-sectional area and diameter of the sucker rod string as it is removed from the well to determine a rod profile; and a tubing sensor for sensing and measuring wear, cross-sectional area, corrosion pitting, and/or holes or splits in the production tubing string as it is removed from the well to determine a tubing profile. A computer system, which may broadly include a central server-computer, a data acquisition computer system, and circuitry connected to the individual two or more sensors, is in communication with the two or more sensors for computing and comparing two or more of the respective deviation profile, rod profile, and tubing profile as a function of depth in the well. The computer preferably compares all three of the deviation profile, rod profile, and tubing profile.
In one embodiment, the computer outputs a wear mitigation solution, which may include installing or repositioning rod guides with respect to specific depth zones of the sucker rod string, lining the production tubing string with a polymer lining at specific depths, employing a tubing rotator to rotate the production tubing string, employing a sucker rod rotator to rotate the sucker rod string, changing pump size, stroke or speed, changing the diameter of a section of the sucker rod string, or replacing one or more segments of the production tubing string or sucker rod string.
The computer may output a visual representation of the comparison of two or more of the deviation profile, rod profile, and tubing profile. The visual representation may include a graphical display of two or more of the deviation profile, rod profile, and tubing profile. The visual representation may also include a three dimensional plot of the deviation profile, accompanied by other rod wear and tubing wear data.
In some embodiments, the computer compares two or more of the deviation profile, rod profile, and tubing profile with two or more previously performed profiles. The computer may also compare one or more of the deviation profile, rod profile, and tubing profile from the well system with profiles from another well, such as in a field of wells.
In one embodiment, a marking method is included for marking segments of one or both of the production tubing string and the sucker rod string when pulled from the well. A tracking device is responsive to the markings on the segments as they are inserted into the well, and a computer is in communication with the tracking device for tracking the relative position of each of the segments of the respective production tubing string and sucker rod string. Typically, the markings will comprise bar code markings, and the tracking device will comprise a bar code reader for reading the bar code markings.
The deviation sensor preferably comprises three pairs of gyroscopes and three pairs of accelerometers, with each pair positioned orthogonally with respect to the two other pairs. The rod sensor preferably comprises one or more of a magnetic flux sensor, Hall effect sensor, an LVDT, a laser micrometer and a laser triangulation sensor. The tubing sensor comprises one or more of a magnetic flux sensor and a Hall effect sensor.
Some embodiments include a plurality of differently sized sensor inserts for accommodating a plurality of diameters of the sucker rod string and production tubing. Each sensor insert may include a plurality of rod sensors and a plurality of tubing sensors. A sensor barrel selectively receives each of the differently sized sensor inserts.
The rod sensor typically senses and measures a coupling that joins segments of the sucker rod string, diameter of the coupling, and then measures one or more of wear to a rod guide, rod diameter, rod cross-sectional area, and pitting. The tubing sensor typically senses and measures one or more of tubing wear cross-sectional area, wall thickness, and pitting. The deviation sensor typically senses and measures one or more of wellbore dogleg severity, inclination angle, change in inclination angle and azimuth.
In some embodiments, the wear evaluation system is tailored to specifically evaluate one or more of wear and corrosion to a string as it is pulled from the well, whether that be a rod string or a production tubing string. Segmented rod strings include multiple segments coupled with larger diameter couplings. The magnetic sensing devices and/or laser micrometer and/or laser triangulation sensors may be radially spaced from the rod string, such that they do not interfere with the larger diameter couplings.
The foregoing is intended to give a general idea of the invention, and is not intended to fully define nor limit the invention. The invention will be more fully understood and better appreciated by reference to the following description and drawings.
A preferred embodiment of a wear evaluation system is indicated generally at 10 in
Correlation of these criteria is vastly more useful than merely determining the individual profiles. For example, analysis of wear detected on the inside surface of tubing 20 alone, without depth-correlated wear to rod 18 or rod coupling 19, at a depth where the deviation profile shows the wellbore to be vertical and straight may indicate that the observed tubing wear is unrelated to this particular wellbore. Alternatively, detection of rod wear on the tubing consistent with and related to sucker rod couplings diameter loss at the same depth, over several hundred feet, in an area where there is a measured material inclination from vertical, would indicate that rod guides would very effectively mitigate tubing wear and thereby extend well production time. Such a correlation analysis is essential for the accurate identification of the root cause of the condition and may only be performed with sufficient data.
A variety of sensor types are available for use with the sensor package 12. In
The rod sensor may obtain data such as wear to the coupling 19 that joins segments of the sucker rod string 18, minimum measured diameter of the coupling 19, wear to a rod guide 35, rod diameter, rod cross-sectional area, and rod pitting. Likewise, the tubing sensor may obtain data such as tubing wear, wall thickness, tubing diameter, cross-sectional area and pitting. The deviation sensor 28 may obtain data such as wellbore dogleg severity, inclination angle, change in inclination angle along the well, azimuth, and change of azimuth.
The rod profile is typically obtained first, the deviation profile second, and the tubing profile third. In a preferred embodiment, the deviation profile is obtained simultaneously with the tubing profile as the tubing is pulled from the well. First, the sucker rod 18 under inspection is pulled from the well by a work-over rig (not shown). As the rig pulls the rod 18, the characteristics of the rod 18 are sensed and measured to determine the rod profile. Data acquisition computer system 14 receives signals from the sensor package 12 and transmits them to the server computer 16. Data acquisition computer system 14 may compute the profiles prior to transmitting to server computer 16, where after the server computer 16 may act as a server. The transmittal between data acquisition computer system 14 and server computer 16 may be by wire, or alternatively by one of a variety of wireless communication technologies known in the art, as conceptually represented by antennas 13 and 15.
Second, after the sucker rod string 18 has been removed from the well 7, a gyroscope & accelerometer-based deviation sensor tool 28 is dropped to the bottom of the well 7 inside the tubing 20. Alternatively, the deviation sensor 28 may be lowered to the bottom of the well 7 on wireline 32. The deviation tool 28 measures and records the output from the accelerometers and gyroscopes in order to calculate inclination, rate of change of inclination and azimuth of the wellbore as the tool 28 is retrieved in the tubing by the work-over rig, or retrieved independently by wireline 32. The tool memory is downloaded into the data acquisition computer system 14 to compute and further process the deviation profile, comparing it with the rod profile and/or tubing profile. This information is also transmitted to server computer 16 for further processing as to the optimum wellbore wear mitigation solution.
Third, the production tubing string 20 is pulled from the well by the work-over rig and inspected similarly to the sucker rod string 18. As the rig pulls the tubing 20, the characteristics of the tubing 20 are sensed to determine the tubing profile. As with the rod string 18, the data acquisition computer system 14 receives signals from the sensor package 12, computes the tubing profile and transmits the information to the server computer 16. At least a portion of this computation may again be carried out by the data acquisition computer system 14.
Having acquired, processed, displayed, recorded and compiled the data, the server computer 16 may then act as a server. This server-computer 16 stores all the raw data, then applies the received information with a software program to calculate a mathematical model of wear to the well system. The model applies correlative techniques and other algorithms to determine a comprehensive wellbore condition profile. The server-computer 16 may then determine an optimal solution for the mitigation of wear within the well 7. The solution may be stored in the computer, acting as a central server, and then optionally transmitted back to the field unit, such as to data acquisition computer system 14, and made available for access over the internet to the appropriate personnel. The server computer 16 may thus be located several hundred feet, or several thousand miles away, enabled by internet and wireless technologies, such as satellite internet access. This is especially useful for management of a field of multiple wells. The server-computer 16 may store wear data for a multitude of wells, providing the convenience of one central processing location, and the ability to correlate not only the rod, tubing, and deviation data from one well, but to correlate like data from the multitude of other wells in common areas, such as to establish or identify patterns or trends common to more than one well within a producing property lease or field.
Having been stored on the server computer 16, all the data assembled in the rod profile, tubing profile, and deviation profile may be communicated and analyzed by means of a graphical database, in countless formats. For instance, the individual profiles may simply be displayed individually in a two-dimensional display. Such a display would only minimally show a correlation between the data, in that all three profiles may be viewed independently, without interrelating them. To provide a more useful analysis, the data from the three profiles is preferably correlated, in that data from one profile is related to data from another profile. As shown in
In one embodiment, an image is created for real-time display of the individual lengths of production tubing, and the sucker rod in the well, by sub depth and circumferential position, thereby displaying flaws on both the rod and tubing while being pulled from a wellbore at the well site. The image is created from signal amplitude, precise location as to depth within the wellbore and position around the circumference of the tube and sucker rod. A signal may be obtained at any desired depth interval, e.g., every foot or every meter. The system provides an accurate representation of the entire tubing or rod string as to depth, flaw size, geometry, wall thickness (as appropriate), radial position and depth within the wellbore. A significant advantage of such a “real-time” image display of a cross-section of the tubing string or rod string as it is being pulled from the well is that a technician trained in the analysis of such images is able to apply human interpolative skills to confirm the image of flaws generated by the imaging software in the computer. This allows for fast classification of individual lengths of tubing or sucker rods, as pulled from the well.
The image produced by the computer may be transmitted on the internet and may be accessed by another internet compatible computer to remotely display the visual representation. A computer at the well or a remote computer may produce a data file, table, or database which may then be accessed through the internet by another computer. A database may be used to remotely display the visual representation, using a graphical viewer operating on the remote computer.
The software system may display 3-dimensional images from multiple wells with the surface location of each well displayed relative to other wells so as to compare the data from one well to other wells in the same producing reservoir.
It is a benefit of the present invention that conditions of multiple wellbores within a common producing field, lease, or area may be correlated and imaged, such as by using color-based common data isogram mapping, which may be applied to a visual display such as shown in
Above the magnetic coil 24 in
Above the LVDT in
In
The sensor package 12 of
The deviation sensor 28 in
The deviation sensor tool 28 may specifically contain three sets of paired micro electrical-mechanical systems (MEMS) Coriolis-effect angular rate gyroscope and accelerometer devices known in the art of inertial navigation and shock measurement. Such devices are not known to have been employed in surveying existing, producing oil and gas wellbores for obtaining a deviation profile. Each pair of MEMS gyroscope and accelerometer devices, respectively, is triaxially positioned orthogonally to each other in the planes X, Y and Z. By initializing the deviation sensor tool relative to an established frame of reference using conventional Cartesian coordinates with a Global Positioning System, and using onboard processing and memory, it is possible to integrate rate of angular change over time into position. The deviation tool or package is thus able to record the inclination and the azimuth of an existing, producing wellbore. The present invention uses less robust, lower operating temperature-capable mass produced Corioles-effect MEMS devices rather than expensive alternative technology Coriolis-effect gyroscopic devices so as to bring the cost below that of a MWD directional survey or multi-shot wireline survey performed during the drilling of a wellbore. By comparison, an entire wellbore evaluation according to the present invention, including computation of rod profile, tubing profile, and deviation profile, may be obtained for less than the cost of a conventional gyroscopic survey. This highlights an important advantage of the invention that, by comparison to current techniques, an exceedingly more comprehensive wellbore analysis for wear, corrosion and deviation can be performed at an affordable price.
In one embodiment, the deviation tool or package utilizes three pairs of MEMS gyroscopes and MEMS accelerometers, positioned orthogonally to each other, to form the basis of a producing wellbore deviation tool. Each pair of a MEMS gyroscope and MEMS accelerometer are positioned in a common plane. The package includes a pressure housing which contains a power supply, e.g., batteries; a microprocessor-controller containing an integrated analog to digital converter and system clock; a system memory to record the output from the accelerometers and gyroscopes, and the MEMS devices.
In order to locate the surface position of the tool, a GPS module may receive satellite positional information to determine position and orientation, thereby establishing the initial position of the tool prior to insertion into the wellbore. The deviation of an existing, previously-drilled, producing wellbore may be determined in three axes, i.e., X, Y & Z, using the three pairs of orthogonally positioned integrated, single chip MEMS Coriolis effect gyroscopes, and three pairs of integrated, single chip MEMS accelerometers as single or dual axis tilt sensors, so as to determine the deviation from vertical in both an azimuthal axis and an inclination axis relative to its surface location. The tool may continuously measure and record the tri-axial deviation of an existing wellbore using the MEMS Coriolis effect gyroscopes and MEMS accelerometers. These devices may input signals to an onboard microcontroller within the tool, and the measurements recorded in an onboard memory within the tool. The deviation sensor 28 may be inserted into production tubing of an existing wellbore and thereby determining the continuous azimuth and inclination of the tubing in situ with the well, without removing the tubing. This information may be passed to the central microcontroller-processor. As the tool is lowered into and removed from the wellbore on a solid or braided wire, the three pairs of MEMS gyroscopes and MEMS accelerometers output analog voltage proportional to negative and positive angular rate and to negative and positive acceleration, respectively. These voltage outputs are then digitized using the integrated analog to digital converter contained in the microprocessor-controller. The onboard memory then records the output of the MEMS devices. Once the tool is removed from the tubing string, the onboard memory may be downloaded to a surface computer. This data is integrated over time and converted into wellbore inclination and azimuth positional information in a manner well known in the art of inertial navigation and wellbore surveying. A deviation profile of the well is then mapped and imaged in the computer, and a printed plot may be obtained.
The radius of curvature of the production tubing (commonly referred to as “dogleg” severity) can be estimated, and may be used to predict side loads between the sucker rod string and production tubing string. The probable locations of rod-on-tubing mechanical wear can thus be determined. Kinks and sags in production tubing within the casing of a previously-drilled producing well may be determined, frequently as a result of failure to adequately pre-load the tubing during installation. The probable points of rod-on-tubing mechanical wear may thus be determined.
Referring now to
The sensors may transmit data to the computer 76 in substantially real time, and the computer may compare signals from each of the sensors, 1-32, as a function of the depth of the portion of the string being examined and as a function of the circumferential position of each sensor in the sensor array 62 and 64. Similarly, sensors from standoff package 66 may be input to the computer 76, so that computer 76 may both correct the signals from the defect sensors as a function of the standoff, as explained above, and may also calculate the effective diameter of the string for that particular depth. This effective diameter determination provides valuable information with respect to both the nature and quality of the defects, and the location of the defects in the well. The computer may also calculate side loading on the string while in the well as a function of the severity of wear and dogleg severity of wellbore inclination and azimuth at particular depths. The computer may then output a plot of side loading as a function of depth, another plot of diameter as a function of depth, and a plot of the corrected defect signals as a function of depth. Each of these signals may also be plotted as a function of a particular circumferential position of one or more sensors within the array.
Signals from sensor packages 62 and 64 are processed through the blocks shown in
For many applications, the operator will desire both deviation information for the well and wear information for the string in the well, so that data from both types of sensors may be coordinated as a function of depth. In other applications, deviation data, i.e. inclination and direction, may not be necessary in order to make a reasonable evaluation of the quality and nature of the wear in the string. For these applications, the computer may thus receive information from the sensor package 64, and preferably also from the deviation package 66, so that a profile of the production tubing string or the rod string as a function of depth and as a function of circumferential position can be plotted, and thus individual lengths of tubing or rod may be classified as to condition in real-time as the tubing is pulled from the well.
Information from the central web server database may be transmitted via the internet for imaging in a client viewer. Deviation profile and rod taper may also be viewed by the customer, as well as 3-D well views, side load dogleg severity views, 3-D field views, tubing taper views, rod condition views, tubing condition views, and cross-wellbore common condition query 3-D views.
The sensors detailed in the above figures are exemplary only, and conceptually illustrating the components that may be included with the wear evaluation system 10. The structure of the sensors is less important than the selection and use of the sensors and the integration and correlation of the data from the sensors. As alluded to previously, the prior art has generally sensed wear of the individual components, such as rod string segments trucked to a remote rod reclamation facility; COROD strings as pulled from the well; tubing strings as pulled from the well; and limited wellbore deviation information obtained during the original drilling of the well. The system correlates this information to obtain more comprehensive information than otherwise available upon separate analysis of the individual components, and performs this operation while all the components of the system remain at the well site. Thus, data from two or more sensors are selected from the group consisting of a deviation sensor movable within the well, either by the tubing as it is retrieved from the well or by wireline, to determine a deviation profile; a rod sensor for sensing wear, diameter, cross-sectional area and pitting of the sucker rod string, including couplings and guides, as it is removed from the well to determine a rod profile; and a tubing sensor for sensing wear, corrosion pitting and cross-sectional area of the production tubing string as it is removed from the well to determine a tubing profile. Some of these conceptually distinct sensors may be physically combined into a single sensor unit, such as sensor insert 26. Although analysis of even two of the profiles is useful, it is preferable in many applications to compute and compare all three of the deviation sensor, rod sensor, and tubing sensor information to determine a comprehensive wellbore profile. The server-computer 16 and/or data acquisition computer system 14 and/or logic circuits that may be contained within any of the individual sensors each may perform some subpart of this computation and comparison.
Integration and analysis of the rod, tubing and deviation profiles further allows for the computation of a wear mitigation solution to correct at least some aspect of performance of the well system. The wear mitigation solution can sometimes be derived by an operator upon viewing and analyzing data, such as displayed in graphical form in the display 50 of
The wear mitigation solution may include strategically positioning rod guides 35 shown in
The wear evaluation system 10 may further include a tracking system 60 detailed conceptually in
The tracking system 60 is useful when repositioning the individual joints of tubing, or rods and especially for future analysis of the elements of the same wellbore. For example, tubing joints having the greatest wear may be repositioned at the top of the string, and it is useful to keep track of this repositioning. Upon subsequent re-evaluation of the wellbore components at a later date, rod and tubing conditions may be compared and thus incremental wear and corrosion determined. Position information may be displayed along with other wear data. For instance, each tubing segment and rod segment may be represented respectively by one of dots 45 and 55 in
Another aspect of the invention provides the significant advantage of evaluating rod wear to segmented sucker rod string 18 in the field. Prior art has been limited to disassembling segmented rod strings and evaluating them off-site, due to interference by the larger diameter couplings 19. According to one specific embodiment of the invention, a rod wear evaluation system 10 comprises a rod sensor included with sensor package 12 for sensing wear to the sucker rod string 18 as it is removed from the well 7 to determine a rod profile. Referring to
According to one embodiment of the invention, an image is displayed of the production tubing and/or sucker rod string in an oil well, by depth and circumferential position, to display flaws on one or both of the rod string and the tubing string while being pulled from a wellbore at the well site. The image is created from components of signal amplitude, precise location as to depth within the wellbore and the circumferential position of the sensor with respect to the tube and/or sucker rod. The imaging system may thereby create a facsimile representation of the entire tubing and/or rod string as to depth, flaw size, geometry, wall thickness (as appropriate), radial position and depth within the wellbore.
The system disclosed herein provides for reducing the dependence of tubing or sucker rod condition classification upon magnetic flux leakage signal amplitude alone. By providing a larger number of circumferentially positioned sensors, digitizing the individual discrete output signals from each sensor within the computer, measuring sensor stand-off from the string under inspection, using high sampling rate digitization electronics for each sensor signal, sampling each sensor by depth, and constructing a real-time image of the sucker rod or tubing as the string passes through the sensor package, string classification may be significantly enhanced.
By comparing signals from individual sensors on both a radial and axial basis and using the axial positional information from a well depth encoder, the computer may build a series of stacked rings representing sucker rod or tubing elements from the producing wellbore. Color may be used to represent cross-sectional area and remaining wall thickness. A brief table representing the methodology used to build the image is shown below, as outlined in the process flow blocks of
In one application, the deviation is retrieved with the normal workover process conducted to remove the tubing string from the well. The tool may be located in a landing nipple or seating sub at the lower end of the tubing string. The dropping speed of the tool may be retarded by utilizing one or more wire brushes that contact the inside surface of the tubing, or using scraper cups which also contact the inside surface of the tubing, or using parachute centralizers.
The tool may be retrieved from the bottom of the wellbore as the tubing is pulled to the surface by the workover rig. Tubing string lengths generally comprise two 30′ sections between a breakout of the string. This results in a deviation or inclination tool standing stationary for a short period while the threaded connections are broken out. The tool may measure deviation of the wellbore both while in motion and while static.
Although specific embodiments of the invention have been described herein in some detail, this has been done solely for the purposes of explaining the various aspects of the invention, and is not intended to limit the scope of the invention as defined in the claims which follow. Those skilled in the art will understand that the embodiment shown and described is exemplary, and various other substitutions, alterations, and modifications, including but not limited to those design alternatives specifically discussed herein, may be made in the practice of the invention without departing from its scope.
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