U.S. patent application number 12/163379 was filed with the patent office on 2008-10-23 for methods and apparatus for monitoring components of downhole tools.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. Invention is credited to Brian S. Shaw, Charles M. Tompkins.
Application Number | 20080257548 12/163379 |
Document ID | / |
Family ID | 36682691 |
Filed Date | 2008-10-23 |
United States Patent
Application |
20080257548 |
Kind Code |
A1 |
Shaw; Brian S. ; et
al. |
October 23, 2008 |
METHODS AND APPARATUS FOR MONITORING COMPONENTS OF DOWNHOLE
TOOLS
Abstract
Disclosed herein is a surface controlled subsurface safety valve
(SCSSV) that includes a moveable component of the SCSSV and a
stationary component of the SCSSV. A sensor element is also
included which is configured to sense position of the moveable
component relative to the stationary component. Further disclosed
herein is a method for sensing position of an object which includes
placing a component comprising magnetostrictive material in a
location calculated to be contacted by a separate component and
causing a stress on the material with the separate component. The
method further includes measuring a change in magnetic permeability
of the material.
Inventors: |
Shaw; Brian S.; (Broken
Arrow, OK) ; Tompkins; Charles M.; (Tulsa,
OK) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
36682691 |
Appl. No.: |
12/163379 |
Filed: |
June 27, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11249809 |
Oct 13, 2005 |
|
|
|
12163379 |
|
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|
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60618826 |
Oct 14, 2004 |
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Current U.S.
Class: |
166/255.1 |
Current CPC
Class: |
E21B 34/10 20130101;
E21B 47/09 20130101 |
Class at
Publication: |
166/255.1 |
International
Class: |
E21B 47/09 20060101
E21B047/09 |
Claims
1. A downhole tool comprising: a moveable component of the downhole
tool; a stationary component of the downhole tool; and a sensor
element positioned and configured to be physically compressible by
a portion of one of the moveable component and the stationary
component against the other of the moveable component and the
stationary component only during some moveable component positions
to sense position of the moveable component relative to the
stationary component.
2. A downhole tool as claimed in claim 1 wherein the sensor element
is a magnetostrictive material having predictable change in
magnetic permeability when stressed.
3. A downhole tool as claimed in claim 1 wherein the sensor is a
mechanical switch type sensor.
4. A downhole tool as claimed in claim 1 wherein the moveable
component is a closure member.
5. A downhole tool as claimed in claim 1 wherein the moveable
component is a flow tube.
6. A downhole tool as claimed in claim 1 wherein the moveable
component is a piston.
7. A downhole tool as claimed in claim 4 wherein the closure member
includes a cam surface configured to bear against the sensor
element to effect the physical compression of the element in one of
an open condition and a closed condition of the closure member.
8. A downhole tool as claimed in claim 6 wherein the piston
includes a magnet and the stationary component supports the sensor
element which is configured to sense the magnet.
9. A downhole tool as claimed in claim 4 wherein the closure member
supports the sensor element such that the sensor element is in
communication with a torsion spring locating against the closure
member.
10. A downhole tool as claimed in claim 10 wherein the sensor
element is in communication with a power spring.
11. A downhole tool as claimed in claim 1 wherein the sensor
element is two sensor elements, one positioned at one end of the
travel of the moveable component and the other positioned at
another end of travel of the moveable component.
12. A downhole tool as claimed in claim 11 wherein the sensors are
carried by the moveable component.
13. A downhole tool as claimed in claim 12 wherein the sensors are
carried by the stationary component.
14. A method for sensing position of an object comprising: placing
a component comprising magnetostrictive material in a location
calculated to be contacted by a separate component; causing a
stress on the material with the separate component; and measuring a
change in magnetic permeability of the material.
15. A method for sensing position for an object comprising: placing
a magnetostrictive material in a location, the location including a
coil; applying a current to the coil; measuring magnetic
permeability of the material; and comparing measured magnetic
permeability to known permeability of the magnetostrictive material
in an unstressed condition.
16. A method for sensing position for an object as claimed in claim
15 where the method further comprises: determining whether the
material is stressed to conclude a position of the object in one of
in contact with the material and spaced from the material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
Non-Provisional application Ser. No. 11/249,809, filed Oct. 13,
2005, which claims the benefit of an earlier filing date from U.S.
Provisional Application Ser. No. 60/618,826 filed Oct. 14, 2004,
the entire disclosure of each of which is incorporated herein by
reference.
BACKGROUND
[0002] Downhole tools having movable components, such as but not
limited to surface controlled subsurface safety valves (SCSSV) are
ubiquitously utilized and sometimes mandated in the hydrocarbon
exploration and recovery art. Both safety systems and simply
exploration or production devices could be improved by enhancements
in means to monitor the positions thereof.
[0003] Using SCSSV's as a particular example, it is important for
an operator to have knowledge of the position and/or condition of
SCSSV's for various reasons. Traditionally, such knowledge has been
gained by monitoring flow volume from the well and control line
pressure at the surface. These methods work well in instances where
the well is operating correctly and where the SCSSV is not an
excessive distance from the source of the control signal. Where
operating parameters of the well are not ideal however, and/or the
SCSSV is a substantial distance from the source, such as in sub-sea
applications, traditional methods for adjudging the position of the
valve are suspect and cannot be relied upon. Doubt in this regard
for any downhole tool is generally the initiator of lost time and
potentially unnecessary expense. Uncertainty is never beneficial to
the hydrocarbon industry; better means of determining things such
as SCSSV position/condition will be welcomed by the art.
SUMMARY
[0004] Disclosed herein is a downhole tool that includes a moveable
component and a stationary component. A sensor element is also
included to sense position of the moveable component relative to
the stationary component.
[0005] Further disclosed herein is a method for sensing position of
an object which includes placing a component comprising
magnetostrictive material in a location calculated to be contacted
by a separate component and causing a stress on the material with
the separate component. The method further includes measuring a
change in magnetic permeability of the material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Referring now to the drawings wherein like elements are
numbered alike in the several figures:
[0007] FIGS. 1A and 1B are schematic views of a closure member and
a stationary element in open and closed positions of a valve;
[0008] FIG. 2 is a schematic view of a closure member with a
torsion spring and sensor;
[0009] FIG. 3 is a schematic view of a closure member with an
alternate sensing arrangement;
[0010] FIG. 4 is a schematic view of a flow tube in a housing with
a sensor arrangement between the power spring and the spring
stop;
[0011] FIG. 5 is a schematic view of a flow tube in a housing with
a sensor arrangement at both ends of travel;
[0012] FIG. 6 is a schematic view of a piston of a valve and a
sensor arrangement to indicate position throughout travel; and
[0013] FIG. 7 is a schematic view of an alternate embodiment of the
concept of FIG. 6;
[0014] FIG. 8 is a schematic view of another alternate embodiment
of the concept of FIG. 7;
[0015] FIG. 9 is a schematic view of a closure member with a
single-position sensing arrangement; it is an alternate embodiment
of the concept of FIG. 1.
DETAILED DESCRIPTION
[0016] Obtaining more knowledge about downhole tools can be
occasioned, even in real time, by careful and creative positioning
of sensory devices. In some embodiments hereof, the sensing
device(s) comprise a magnetostrictive material such as Terfenol-D
commercially available from Etrema Products, Inc. The
magnetostrictive material exhibits different magnetic permeability
when placed under stress, and particularly compression, than it
does when not under stress. Magnetic permeability is measured by
supplying a current to a coil around the magnetostrictive material.
This property is reliable and repeatable and the material itself is
highly robust making Terfenol-D a useful sensing material for
downhole tools. It is to be appreciated that Terfenol-D is but a
single example of a magnetostrictive material and that others with
similar properties could be substituted. In the exemplary
embodiment of Terfenol-D, reference is made to U.S. Pat. No.
6,273,966 which is fully incorporated herein by reference, wherein
Terfenol-D is described in more detail. In the event a check is
desired, a second magnetostrictive device is deployed in proximity
to the first but which is not exposed to the stress creator
intended to be measured. Any permeability change due to conditions
not related to the stress creator being measured will register on
both devices, making resolution of the target stress creator clear
and reliable. In other embodiments hereof permanent magnets, hall
effect sensors and mechanical, electrical or optical limit switches
or optical readers may be employed. In each embodiment the goal is
to obtain more direct and rapid indication of a particular
condition or position of a device downhole, such as for example one
or more of the components of a SCSSV. It is also to be understood
that one or more of the types of sensors may be employed in the
same device and one or more of the same type of sensor may be
employed in the same devices.
[0017] Referring to FIGS. 1A and 1B a schematic representation of a
closure member (such as a flapper valve) portion of a SCSSV is used
to illustrate the inventive concept, which as stated above applies
to other tools as well. The closure member portion of the SCSSV is
illustrated generally at 10. The closure member is disposed in a
housing 12 which includes a sensor element 14. The element 14 is
configured to sense pressure exerted thereon by a cam surface 16 of
closure member 18 (flapper). The closure member pivots around pin
20 and based upon position will exert pressure on element 14 or
will not exert pressure on element 14. FIG. 1A illustrates the
device 10 in a valve closed position and FIG. 1B illustrates the
device 10 in the valve open position. In the open position of FIG.
1B, it is apparent that cam surface 16 has come into contact with
sensor element 14. In the event sensor element 14 is a
magnetostrictive material, a change in magnetic permeability of
sensor element 14 will be measurable to provide an indication that
the flapper 18 is indeed open. Other sensor elements can be
substituted such as magnetic sensors, hall effect sensors, switch
type elements, etc. (FIG. 9) which all would be positioned as is
the illustrated magnetostrictive sensor element 14. Information
obtained by sensor element 14 is communicated to a remote location
such as a surface location by a communication means (not shown)
such as a hydraulic conduit, electrical conductor, optic conductor
or wireless method.
[0018] Referring now to FIG. 2, shown is an illustration of a
flapper valve 18 which is actuated to close by at least one torsion
spring 22. As the arrangement is illustrated, two torsion springs
22 are apparent although it is to be understood that a single
torsion spring is also contemplated. Each of the illustrated
springs 22 include a leg 24. In one embodiment, at least one of the
two illustrated legs 24 rests upon a magnetostrictive material 26
such that upon opening the flapper 18, the magnetostrictive
material 26 is placed under a greater compressive load occasioned
by the tightening of torsion spring 22. It is to be understood that
both illustrated legs 24 could be placed on one portion of material
26 or individual portions of material 26. Compressive stress at
material 26 causes altered magnetic permeability thereof, which
property is remotely readable by current charge. In another
embodiment, similar to the foregoing embodiment, magnetostrictive
material 26 may be substituted for by a switch member where the
benefits of the magnetostrictive material are not needed.
[0019] Referring now to FIG. 3, another alternate embodiment is
schematically illustrated. Flapper 18 is pivotally connected at
hinge pin 20 to flapper housing 12. As illustrated SCSSV 10
includes sensors to verify both the open and closed positions of
the flapper 18. To this end, flapper 18 is endowed with a high
temperature magnet 28 while housing 12 includes a "closed" sensor
30 and an "open" sensor 32. Sensors 30 and 32 are sensitive to a
magnet in proximity thereto and thus can verify a closed or open
position of flapper 18 due to magnet 28 coming into proximity to
sensors 30 and 32, respectively. In one embodiment, the magnet 28
is of permanent type and the sensors 30 and 32 are Hall-effect.
[0020] Sensors 30 and 32 are informationally connected to sensor
electronics 34 which are programmed to interpret what has been
sensed and emit a signal to be propagated to a remote location
along schematic cable 36, which may be hydraulic, electric, optic
or wireless in configuration.
[0021] Referring now to FIG. 4, one of ordinary skill in the art
will appreciate a schematically represented flow tube 41 within a
housing 42. The flow tube 41 is moveably positioned by a piston 66
and this movement is resisted by a power spring 43, the stationary
end of which is fitted with a sensor substantially similar to that
described in conjunction with FIG. 2. In one embodiment, the end of
the power spring 43 rests upon a magnetostrictive material 26 such
that upon opening the SCSSV, the magnetostrictive material 26 is
placed under a greater compressive load occasioned by the
compression of power spring 43. Compressive stress at material 26
causes altered magnetic permeability thereof, which property is
remotely readable by current charge. In another embodiment, similar
to the foregoing embodiment, magnetostrictive material 26 may be
substituted for by a switch member where the benefits of the
magnetostrictive material are not needed.
[0022] Referring now to FIG. 5, one of ordinary skill in the art
will appreciate a schematically represented flow tube 41 within a
housing 42 and limited in axial movement by a top sub 44 and a
bottom sub 46. This illustration is limited to a flow tube and
housings relevant thereto but should be understood to be some of
the components of a SCSSV. The illustration has been done in this
way to more readily show the sensor elements 48 and 50. In this
embodiment, verification is available for position of the flow tube
41 in the "open" position or the "closed" position by receiving a
signal from sensor element 48 or sensor element 50. In either
position one of the two identified sensors will be fully loaded
while the other will be fully unloaded. Where neither is loaded,
the tube is in mid-stroke and where both are loaded there is
significant indication that one or both sensors are malfunctioning.
Based upon exposure to the foregoing embodiments described herein,
one will appreciate that the sensor elements 48 and 50 may comprise
magnetostrictive material functioning as noted above, or
mechanical, electrical or optic switches.
[0023] In yet another embodiment, referring to FIG. 6, a magnetic
or optical sensing device 60, such as a hall effect sensor or
optical "bar-code" reader, is positionable within a piston housing
62 operably near piston 66 with magnetic or optical indicator 64
running down the side of piston 66 such that the amount of movement
of indicator 64 mounted to piston 66 can be measured as it passes
device 60. As the indicator 64 is fixedly mounted at piston 66, the
movement of indicator 64 is the same as the movement of piston 66.
Alternatively, a row or column of individual units of
magnetostrictive material can be utilized to register variable
positioning of the piston 66 or other moving device in near or real
time. This occurs by altering magnetic permeability of the column
or row in sequence. Direction of movement and speed of movement are
resolvable in this way.
[0024] Referring now to FIG. 7, a magnetic sensing device 60, such
as a hall effect sensor, is positionable within a piston housing 62
operably near piston 66 with magnetic indicator 64 mounted at a
single position on piston 66 such that the movement of piston 66
can be measured as it passes device 60. As the magnetic indicator
64 is fixedly mounted at piston 66, the movement of indicator 64 is
the same as the movement of piston 66.
[0025] Referring now to FIG. 8, the same arrangement as described
in FIG. 7 is illustrated with sensing element 60 located in a hole
61 in piston housing 62 (and as illustrated filling the hole such
that the hole is not separately visible in the drawing) running
parallel to and located in proximity to the primary piston 66.
[0026] Referring now to FIG. 9, a schematic representation of a
closure member 18 (such as a flapper valve) portion of a SCSSV is
illustrated generally. The closure member includes a magnetic
element 70 positioned such that as the closure member 18 pivots
around the flapper hinge 20 and moves into the full-open position
the element 70 comes into contact with the sensing mechanism 72
mounted on sensing bracket 74. The sensing mechanism registers the
change in magnetic field and transmits this information such that a
"full open" signal is sent to the surface.
[0027] It is important to understand that all of the above
embodiments are exemplary in nature and that the concept of
positioning a sensor element relative to a moveable and stationary
component to sense relative position of the two components is
applicable to all tools that include a moveable and stationary (or
even another moveable) component. These include such as sliding
sleeves, cross-over tools moveable service tools, any type of
safety valve, open/close sleeves, etc.
[0028] While preferred embodiments have been shown and described,
various modifications and substitutions may be made thereto without
departing from the spirit and scope of the invention. Accordingly,
it is to be understood that the present invention has been
described by way of illustration and not limitation.
* * * * *