The present disclosure relates generally to wellbore completion operations and, more particularly (although not necessarily exclusively), to tubing encased conductors.
Tubing encased conductors (TECs) are placed downhole in a wellbore for providing power to downhole devices from the surface and transmitting data from downhole devices back to the surface. Downhole devices may include but are not limited to sensors. It can be desirable to place sensors at multiple locations along the wellbore. Placement of each sensor along the TEC can require creating a splice, join, or new termination in the TEC. Each sensor can require as many as three points for connecting to a power cable in the TEC. This results in at least one, and potentially three points where the integrity of the TEC is breached and sealed. Each of these points is at risk of leaking wellbore fluids into the core of the TEC, which may result in a short circuit. A single leak could cause failure of an entire downhole system powered by the TEC. The reliability of the entire downhole system powered by the TEC may be depend on the reliability of these points.
Certain aspects and examples of the present disclosure relate to wireless transmission and reception of electrical signals to a device positioned downhole, for example but not limited to a sensor, via a TEC without a wired connection between the device and the TEC. A TEC may contain at least one electrical conductor within a metal tubing. The metal tubing may provide the at least one electrical conductor protection from abrasion and protection from fluids. The electrical conductor may carry power and data to downhole tools. Connecting a downhole tool to the TEC may, in some instances, require cutting the tubing, connecting the electrical conductor to the downhole tool, and wielding the tubing to the body of the downhole tool. Such a process can be expensive and time consuming. The present disclosure teaches methods and assemblies for transmitting data (i.e. transmission and/or reception of digital signals corresponding to commands or data) between a downhole device and a TEC and/or providing power to the downhole device from a TEC without hardwiring the downhole device to the TEC. Current may produce a magnetic field around a wire that is characteristic of the current within the wire. The magnetic field around the wire may provide power to the downhole device or may correspond to data being transmitted to the downhole device. Also, altering or producing a magnetic field around the wire may produce or influence the current within the wire. The magnetic field produced or altered around the wire may impart data via influencing the current in the wire.
Wireless transmission and reception of electrical signals between a downhole device and a TEC may improve wellbore systems' functioning by alleviating the need to physically hardwire the downhole device to the TEC which may cause damage to the TEC thus negatively impacting the functioning of the well system. Wireless transmission and reception of electrical signals along the TEC may also allow for finer control of production in the well system by using wired electronics, such as electronic inflow control valves (eICVs) to act as data hubs for wireless downhole devices. For example, elCVs, wired to the TEC, could receive electrical signals from nearby wireless sensors instead of the wireless sensors having to send signals to the surface, providing a short hop for communication between the wireless sensors and the EICV's electrical signal.
Transmitting and receiving electrical signals locally, via a network of wired and wireless downhole tools could also allow for a faster means of communication than transmitting every signal to the surface and receiving every signal from the surface via the TEC. The potential for increased speed in transmitting and receiving electrical signals may be explained by an increase in bandwidth that may be afforded by higher frequency signals sent and received locally. Higher frequency signals may be better suited for higher bandwidth applications than lower frequency signals, whereas lower frequency signals may be better suited to retaining coherence along a significant distance, such as a path from a down-well tool to the surface.
The electrical signals, received or transmitted wirelessly or with a wired connection to the TEC, may control any downhole device. For instance, data from a sensor wirelessly interfacing with the TEC could instruct a wired EICV to open, close, or adjust fluid flow through the EICV. In other examples a wireless downhole device may transmit via electrical signals commands to another downhole device or tool related to a hydrostatic system, setting a production packer, setting a sliding sleeve operable to provide a flowpath between an oilfield tubular and an annulus of a wellbore, or actuating a disconnect reel, or other command. Examples of oilfield tubulars include jointed pipe and coiled tubing.
The electrical signals may include data (including commands) that may be encoded in varying current amperage, voltage amplitude shifts, voltage phase shifts, voltage frequency shifts, timing shifts or other characteristics of alternating currents present within at least one alternating current within a TEC. Alternating current may be a time varying current where the frequency of the varying current is greater than 50 Hz. Data (including commands) may be encoded in varying current amperage of a direct current present within the TEC. Direct current may be a quasi-static current that may have a non-zero average current value. Data encoding may be achieved by varying voltage at a voltage source at the surface from which the TEC originates. The data encoded in the alternating current within a TEC may accompany an alternating current of a different frequency, used for power transmission. Also, the data encoded in the alternating current within a TEC may accompany a direct current used for power transmission.
Data encoded in alternating variable current within the TEC may be received as variations in a resulting magnetic field by a magnetic field sensor. In some examples, variations in the resulting magnetic field may be received by a magnetometer that measures magnetic field. In one example, the magnetometer is a transformer. The transformer may include but is not limited to a ferromagnetic ring that may surround the TEC such that the magnetic field created by the current within the TEC passes through the ferromagnetic ring. The transformer may also include a wire coil around the ferromagnetic ring that may transfer the magnetic flux passing through the ferromagnetic ring into electrical current representative of the data encoded in the current within the TEC. In some examples, the ferromagnetic ring may include ferrite though any suitable ferromagnetic material may be used. The term ferromagnetic is intended to include ferrimagnetic and paramagnetic behaviors. Additional examples of ferromagnetic materials include nickel-iron alloys such as Permalloy and mu-metal, iron, steel, and nickel.
Energy may be harvested from an alternating current within the TEC by a transformer. The transformer may include a ferromagnetic ring that may surround the TEC such that the magnetic field created by the current within the TEC passes through the ferromagnetic ring. The transformer may also include a wire coil around the ferromagnetic ring that may convert the magnetic flux passing through the ferromagnetic ring into electrical current that may be sufficient to power at least one downhole tool, sensor, control valve, or other device. The sensor may operate at a higher voltage and lower current than that of the TEC.
Illustrative examples are given to introduce the reader to the general subject matter discussed herein and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative aspects, but, like the illustrative aspects, should not be used to limit the present disclosure.
The AC current within the electrical conductor 202 may be on top of a DC current flowing within the electrical conductor 202. Data may be encoded in varying current amperage, voltage amplitude shifts, voltage phase shifts, voltage frequency shifts, timing shifts or other characteristics of the AC current. Data encoding may be achieved by varying voltage at a voltage source above a surface from which the TEC 106 originates. Data encoding may also be achieved by encoding an AC current created downhole by the wired device 108. Examples of encoded data may include but are not limited to data corresponding to draw down rate flow rate, fluid viscosity, pressure, temperature, chemical composition, potential of hydrogen (pH) values, water composition, or operational status of the wired device 108
The magnetic field 212 produced within the ferromagnetic ring 112 by the current 200 may possess a time-varying magnetic field values that parody the variations in the characteristics of the current 200. The coil 208 may obtain an induced current from the magnetic field 212 produced within the ferromagnetic ring 112. The induced current within the coil 208 may retain values that parody the variations within the current 200 and contain encoded data within the current 200. The induced current may also be sufficient to power the wireless device 110 attached to the ferromagnetic ring 112 by the coil 208.
The wired device 108, may be able to serve as a data hub, capable of receiving data form the surface or transmitting data to the wireless device 110. The wireless device 110 may be calibrated to accept electrical signals either associated with a particular channel or associated with a channel specific to the wireless device 110. A turbine may be placed proximal to the wireless device 110 for the purpose of supplying energy to the wireless device 110.
The transformer 315 may create an AC magnetic flux that is concentrated in the ferromagnetic ring 310. The AC magnetic field may create an AC current in the coil 312. The transformer 315 may inject an AC electrical signal into the TEC 302. The transformer 315 may create a short-duration AC current within the TEC 302. A resulting AC current could be at a different frequency than a power frequency, which may be detected with greater fidelity uphole. The resulting AC current can even be an AC signal on a DC within the TEC 302. Electrical energy could be collected in a capacitor bank to accumulate sufficient energy to amplify a signal of greater fidelity. The transformer 315 can use a time-varying magnetic field to induce an AC signal in the TEC 302. The current within the electrical conductor 304 may include any combination of alternating currents or direct currents of varying phase or voltage amplitude. Data may be encoded in varying current amperage, voltage amplitude shifts, voltage phase shifts, voltage frequency shifts, timing shifts or other characteristics of alternating currents present within the current.
Data encoding may be achieved by varying voltage at a voltage source above the surface from which the TEC 302 originates. Examples of encoded data may include but are not limited to draw down rate flow rate, fluid viscosity, pressure, temperature, chemical composition, potential of hydrogen (pH) values, water composition, or operational status of the wired device 324. The magnetic field 320 produced within the ferromagnetic ring 310 by the current may possess a time-varying magnetic field that parody the variations in the characteristics of the current.
The wireless device 314 may transmit an electrical signal to the voltage source 318 for amplification. The electrical signal may correspond to a command, a measurement, or other data. The voltage source 318 may use energy stored within the capacitor 316 to amplify the electrical signal across the wire 313 shaped into a coil 312 by providing a bias within the alternating current. An alternative means of energy storage, including but not limited to additional capacitors, at least one chemical battery, or any combination of devices suitable for storing electrical energy may be used in place of the capacitor 316. A turbine may be placed proximal to the wireless device 314 for the purpose of supplying energy to the voltage source 318 or the wireless device 314. The electrical signal transmitted through the coil 312 may alter the magnetic field 320 within the ferromagnetic ring 310 such that changes in the magnetic field 320 parody the electrical signal transmitted through the wire 313. The alterations in the magnetic field 320 may alter characteristics of the electrical signal encoded in the AC current within the TEC 302, thereby encoding the electrical signal originating from the wireless device 314 into the AC current. The AC current containing the electrical signal may be on top of a DC current flowing within the electrical conductor 304 within the TEC 302. Wired electronics may be able to serve as a data hub, capable of receiving data from the surface or receiving data from the wireless device 314. The wireless device 314 may be calibrated to transmit electrical signals either associated with a particular channel or associated with a channel specific to the wireless device 314.
The current 406 within the electrical conductor 404 may include any combination of alternating currents or direct currents of varying phase or voltage amplitude. A constant resistive load may be placed at either end of the TEC 402. Data may be encoded in varying current amperage, voltage amplitude shifts, voltage phase shifts, voltage frequency shifts, timing shifts or other characteristics of alternating currents present within the current 406. Data encoding may be achieved by varying voltage at a voltage source above the surface from which the TEC originates. Data encoding may also be achieved by changing current flow with the wired device 424. Examples of encoded data may include but are not limited to draw down rate flow rate, fluid viscosity, pressure, temperature, chemical composition, potential of hydrogen (pH) values, water composition, or operational status of the wired device 424. A magnetic field produced within the harvesting ring 420 by the current 406 may possess a time-varying magnetic field that parodies variations in the characteristics of the current 406. The harvesting coil 422 may obtain an induced current from the magnetic field produced within the harvesting ring 420. The induced current within the coil may retain values that parody variations within the current 406 and contain encoded data within the current 406. The induced current obtained at the harvesting coil 422 may also be used to charge the capacitor 416 or another means of electrical energy storage, such as a capacitor bank, a chemical battery, a bank of chemical batteries, or a combination of batteries and capacitors.
The wireless device 414 may transmit an electrical signal to the voltage source 418 for amplification. The voltage source 418 may use energy stored within the capacitor 416 to amplify the electrical signal across the wire 413 shaped into the transmitting coil 412. An alternative means of energy storage, including but not limited to additional capacitors, at least one chemical battery, or any combination of devices suitable for storing electrical energy may be used in place of the capacitor 416. The electrical signal transmitted through the transmitting coil 412 may alter a magnetic field within the transmitting ring 410 such that changes in the magnetic field parody the electrical signal transmitted through the wire 413 shaped into the transmitting coil 412. Alterations in the current 406 may affect an output voltage 408.
Wired electronics, such as the wired device 424 may be able to serve as a data hub, capable of receiving data from the surface, receiving data from the wireless device 414 or similar sensors, transmitting data to the wireless device 414 or similar sensors, and routing data from the wireless device 414 or similar sensors to the surface. The wireless device 414 may be calibrated to transfer and/or receive electrical signals either associated with a particular channel or associated with a channel specific to the sensor 414.
A constant resistive load may be placed at either end of the TEC 502. Data may be encoded in varying current amperages of direct current present within the current. Data encoding may be achieved by varying voltage at a voltage source above the surface 512 from which the TEC 502 originates. Data encoding may also be achieved by changing current flow with the wired ICV 510. Examples of encoded data may include but are not limited to commands to a device or tool downhole. For example, encoded data may correspond to a command to change a fluid restriction, to activate the downhole tool 514, to release the downhole tool 514, to adjust the programming of the downhole tool 514. Encoded data may also include sensor data, for example but not limited to, data corresponding to a draw down rate flow rate, fluid viscosity, pressure, temperature, chemical composition, potential of hydrogen (pH) values, or water composition. The magnetic field 508 passing through the magnetic field detector 506 may possess a time-varying magnetic field that parodies the variations in the current. The magnetic field detector may interpret the time-varying magnetic field to derive the data encoded in the current. The sensor 506 can detect a DC current flowing through the TEC, so the data may be encoded with changes in the level of the DC current flow. Examples of magnetic field detector 506 include Hall effect sensors, magneto-resistive sensors such as giant magnetoresistive sensors (GMR), anisotropic magnetoresistive sensors (AMR), and tunnel magneto-resistive (TMR) sensors, and inductive coil sensors.
Wired electronics, such as the wired ICV 510 may be able to serve as a data hub, capable of receiving data from the surface 512 and routing the data to magnetic field sensors 506 downhole of the ICV 510. The magnetic field sensor 506 may be calibrated to accept electrical signals either associated with a particular channel or associated with a channel specific to the magnetic field sensor 506. The magnetic field sensor 506 may be in electrical communication with a downhole device powered by a turbine.
The electronics 512 may translate commands received by the magnetic field detector 506 from the TEC 502. The electronics 512 may regulate an energy storage 516, such as a chemical battery, so that the electronics 512 can relay commands to the downhole tool 514. Commands may cause the downhole tool 514 to perform a wellbore function, such as setting a packer sleeve, dispensing cement, perforating a geological formation, or gathering a sample. Other wellbore functions are also possible in other examples.
The wet connect 610 may transfer electrical energy via magnetic induction or capacitive charging. The alternating current may optionally flow through a AC-DC transformer 604. The DC-AC transformer 602 and the optional AC-DC transformer 604 may create both a direct current for powering wired ICV nodes 608 as well as an alternating current. Data may be encoded in varying current amperage, voltage amplitude shifts, voltage phase shifts, voltage frequency shifts, timing shifts or other characteristics of alternating currents present within the current 200. Data may be encoded in varying current amperage of a direct current within the TEC. Data encoding may be achieved by varying voltage at a voltage source above a surface from which the TEC originates. Examples of encoded data may include but are not limited to draw down rate flow rate, fluid viscosity, pressure, temperature, chemical composition, potential of hydrogen (pH) values, water composition, or operational status of a wired device.
A magnetic field produced within a ferromagnetic ring or across a magnetic field detector of an electronic inflow control device node 606 may possess varying magnetic flux values that parody the variations in characteristics of the alternating current within the portion of the TEC 600 downhole of the DC-AC transformer 602. The electronic inflow control device node 606 may interpret data encoded in the variations of characteristics of the alternating current. The electronic inflow control device nodes 606 or ICV nodes 608 may be calibrated to accept electrical signals either associated with a particular channel or associated with a channel specific to a given electronic inflow control device node 606 or ICV node 608.
In some aspects, systems for wireless transmission and reception of electrical signals via tubing encased conductor are provided according to one or more of the following examples:
As used below, any reference to a series of examples is to be understood as a reference to each of those examples disjunctively (e.g., “Examples 1-4” is to be understood as “Examples 1, 2, 3, or 4”).
Example 1 is a system comprising: a tubing encased conductor (TEC); a transformer configured to inductively couple to the TEC; and a downhole device, coupled to the transformer, the downhole device comprising a transceiver configured to receive, from the transformer, digital signals encoded in a variable current in the TEC.
Example 2 is the system of example(s) 1, wherein the transceiver of the downhole device is further configured to transmit digital signals encoded in an alternating current to an at least one additional downhole device electrically coupled to the TEC.
Example 4 is the system of any of example(s) 1-2, further comprising a second transformer inductively coupled to the TEC, configured to transmit digital signals encoded in an alternating current of the TEC.
Example 4 is the system of any of example(s) 1-2, further comprising a wired downhole tool configured to couple to the TEC, the wired downhole tool configured to transmit digital signals corresponding to a command to the downhole device.
Example 5 is the system of any of example(s) 1-4, wherein digital signals encoded in an alternating current are encoded via variations in voltage, frequency, phase, or any other suitable parameter of the alternating current.
Example 6 is the system of any of example(s) 1-5, wherein the downhole device is configured to receive electrical power via the transformer.
Example 7 is the system of any of example(s) 1-6, wherein digital signals are encoded in an alternating current and are configured to traverse a direct current.
Example 8 is the system of any of example(s) 1-7, wherein digital signals transmitted by a wired downhole tool to the downhole device are of a higher frequency than digital signals originating from or directed to a processor at a surface.
Example 9 is the system of any of example(s) 1-8, further comprising: a direct current to alternating current transformer coupled above a wet-connect using an AC wet connect, an alternating current to direct current transformer coupled below the wet-connect for providing a direct current power source for the downhole device wired to the TEC; and an alternating current source for communication with the downhole device.
Example 10 is a system comprising: a tubing encased conductor (TEC); a transformer configured to inductively couple to the TEC; and a downhole device, coupled to the transformer, the downhole device comprising a transceiver configured to transmit, from the transformer, digital signals encoded in a variable current in the TEC.
Example 11 is the system of example(s) 10, wherein the transceiver of the downhole device is further configured to receive data from an at least one additional downhole device electrically coupled to the transceiver.
Example 12 is the system of any of example(s) 10-11, further comprising a second transformer inductively coupled to the TEC, configured to receive digital signals encoded in an alternating current of the TEC.
Example 13 is the system of any of example(s) 10-12, further comprising a capacitor coupled to the downhole device, configured to supply energy for transmission of digital signals encoded in an alternating current of the TEC.
Example 14 is the system of any of example(s) 10-13, wherein the digital signals are encoded in an alternating current and are encoded via variations in voltage, frequency, phase, or any other suitable parameter of the alternating current.
Example 15 is the system of any of example(s) 10-14, wherein the downhole device is configured to receive electrical power via the transformer.
Example 16 is the system of any of example(s) 10-15, wherein digital signals are encoded in an alternating current and are configured to traverse a direct current.
Example 17 is the system of any of example(s) 10-16, wherein digital signals received by a wired downhole tool to the downhole device are of a higher frequency than digital signals originating from or directed to a processor at a surface.
Example 18 is the system of any of example(s) 10-17, further comprising: a direct current to alternating current transformer coupled above a wet-connect using an AC wet connect, and an alternating current to direct current transformer coupled to the wet-connect for providing a direct current power source for the downhole device wired to the TEC as well as providing an alternating current electrical signal in addition to the direct current for communication with the downhole device.
Example 19 is a system comprising: a tubing encased conductor (TEC) for transmitting a direct current; a wireless device positioned downhole comprising: a magnetic sensor for wirelessly receiving a digital signal encoded in the direct current of the TEC, for controlling the wireless device positionable downhole; and a wired downhole tool coupled to the TEC, the wired downhole tool configured to transmit the digital signal to the wireless device positionable downhole via the TEC.
Example 20 is the system of example(s) 19, wherein the digital signal is encoded in the direct current via varying current amperage of the direct current.
The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure.