U.S. patent application number 12/061205 was filed with the patent office on 2009-10-08 for control of downhole devices in a wellbore.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. Invention is credited to Gerald Heisig, Michael Koppe, John D. Macpherson, Ralf Zaeper.
Application Number | 20090250225 12/061205 |
Document ID | / |
Family ID | 41132198 |
Filed Date | 2009-10-08 |
United States Patent
Application |
20090250225 |
Kind Code |
A1 |
Zaeper; Ralf ; et
al. |
October 8, 2009 |
CONTROL OF DOWNHOLE DEVICES IN A WELLBORE
Abstract
A system for performing a task in a borehole, the system
including: a downhole tool configured for disposition into the
borehole, the downhole tool also configured to perform the task; a
processing unit disposed remote to the downhole tool, the
processing unit configured for initiating a command signal; and a
broadband communication system for coupling the downhole tool and
the processing unit, the broadband communication system configured
to transmit the command signal to the downhole tool to perform the
task.
Inventors: |
Zaeper; Ralf; (Hannover,
DE) ; Macpherson; John D.; (Spring, TX) ;
Koppe; Michael; (Lachendorf Niedersachsen, DE) ;
Heisig; Gerald; (Celle Lower Saxony, DE) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
41132198 |
Appl. No.: |
12/061205 |
Filed: |
April 2, 2008 |
Current U.S.
Class: |
166/374 ;
166/250.15; 166/373 |
Current CPC
Class: |
E21B 47/12 20130101 |
Class at
Publication: |
166/374 ;
166/250.15; 166/373 |
International
Class: |
E21B 34/10 20060101
E21B034/10; E21B 43/12 20060101 E21B043/12; E21B 34/06 20060101
E21B034/06 |
Claims
1. A system for performing a task in a borehole, the system
comprising: a downhole tool configured for disposition into the
borehole, the downhole tool also configured to perform the task; a
processing unit disposed remote to the downhole tool, the
processing unit configured for initiating a command signal; and a
broadband communication system for coupling the downhole tool and
the processing unit, the broadband communication system comprising
a plurality of distributed devices configured to provide stable
control in real time over the downhole tool to perform the
task.
2. The system as in claim 1, further comprising a sensor coupled to
the broadband communication system wherein the broadband
communication system is configured to transmit data from the sensor
to the processing unit, the sensor disposed on a drill string
comprising the downhole tool.
3. The system as in claim 2, wherein the processing unit is
configured to display the data.
4. The system as in claim 2, wherein the processing unit comprises
an algorithm for automatically initiating the command signal.
5. The system as in claim 2, wherein the processing unit is
configured to receive an input from an operator to initiate the
command signal.
6. The system as in claim 1, wherein the broadband communication
system comprises at wired pipe as a transmission medium.
7. The system as in claim 6, wherein the wired pipe comprises a
broadband cable.
8. The system as in claim 1, wherein the broadband communication
system comprises an optical fiber as a transmission medium.
9. The system as in claim 1, wherein the broadband communication
system is configured to transmit a low frequency radio wave through
at least one of the earth and the borehole.
10. The system as in claim 1, wherein the broadband communication
system is configured to transmit an acoustic wave through a drill
string coupled to the downhole tool.
11. The system as in claim 1, wherein the task comprises operating
one of an underreamer, a flow diverter and a disconnect coupled to
the downhole tool.
12. (canceled)
13. The system as in claim 1, wherein the task comprises operating
a whip stock.
14. The system as in claim 13, wherein operating comprises setting
an angle.
15. (canceled)
16. The system as in claim 1, wherein the task comprises initiating
a perforating device.
17. The system as in claim 1, wherein the task comprises at least
one of placement and expansion of at least one of a casing and
completion device.
18. The system as in claim 1 wherein the task comprises one of
energizing the downhole tool and de-energizing the downhole
tool.
19. (canceled)
20. A method for performing a task in a borehole, the method
comprising: placing a downhole tool for performing the task in the
borehole; initiating a command signal with a processing unit; and
transmitting the command signal using a broadband communication
system comprising a plurality of distributed devices to the
downhole tool to perform the task; the plurality of devices
preventing undamped oscillations during the performing.
21. The method as in claim 20, further comprising transmitting a
measurement from a sensor to the processing unit using the
broadband communication system, the sensor disposed on a drill
string comprising the downhole tool.
22. The method as in claim 20, further comprising an operator
inputting a command to the processing unit.
23. The method as in claim 20, wherein the processing unit
automatically initiates the command signal.
24. The method as in claim 20, wherein the method is implemented by
machine-executable instructions stored on machine-readable
media.
25. An apparatus for controlling a task in a borehole, the
apparatus comprising: a downhole tool configured for disposition
into the borehole, the downhole tool also configured for performing
the task; a sensor in operable communication with an aspect of the
task; a controller in operable communication with the downhole tool
and the sensor, the controller configured to receive a measurement
from the sensor and to provide closed-loop control of the downhole
tool for controlling the task; and a broadband communication system
comprising a plurality of devices for providing stable control in
real time and for coupling the sensor and the controller and for
coupling the controller and the downhole tool.
26. The apparatus as in claim 24, wherein the controller is
configured to receive manual input.
27. The system as in claim 1, wherein the plurality of distributed
devices prevent undamped oscillations in a closed-loop control
system of the communication system.
28. The method as in claim 20, further comprising performing a
diagnostic check of the downhole tool with at least one device from
the plurality of devices.
29. The method as in claim 20, wherein the preventing is in
real-time.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention disclosed herein relates to controlling
apparatus disposed in a borehole and, in particular, to initiating
performance of a task downhole.
[0003] 2. Description of the Related Art
[0004] Various types of drill strings are deployed in a borehole
for exploration and production of hydrocarbons. A drill string
generally includes drill pipe and a bottom hole assembly. Sensors,
electromechanical devices, or electrohydraulic devices may also be
deployed along the drill string. The bottom hole assembly and
distributed devices can be used for drilling, sampling, and logging
for example.
[0005] Depending on the purpose of the drill string, the drill
string assembly may include a device that performs a task on
command. For instance, the task may include opening a flow
diverter. Many of these tasks are typically initiated by mechanical
actuation. Unfortunately, mechanical actuation presents some
disadvantages. The disadvantages include reliability and a time
delay between deciding to perform the actuation and the actuation
of the device. The time delay may also include a delay in obtaining
information upon which to base the decision.
[0006] An example of a time delay problem can occur while drilling.
During drilling operations, fluid may suddenly enter the borehole.
It is important to quickly control the well to prevent a blowout.
However, to provide the proper compensating measures, the operator
needs certain information such as whether the fluid is oil or gas.
The amount of time delay can mean the difference between a blowout
and a controlled well.
[0007] Therefore, what are needed are techniques to reliably
actuate an apparatus disposed in a borehole. Preferably, the
techniques also provide information quickly to an operator with
which to base a decision in a timely manner.
BRIEF SUMMARY OF THE INVENTION
[0008] Disclosed is a system for performing a task in a borehole,
the system including: a downhole tool disposed in the borehole, the
downhole tool configured to perform the task; a processing unit for
initiating a command signal; and a broadband communication system
coupled to the downhole tool and to the processing unit, the
broadband communication system configured to transmit the command
signal to the downhole tool to perform the task.
[0009] Also disclosed is one example of a method for performing a
task in a borehole, the method including: placing a downhole tool
for performing the task in the borehole; initiating a command
signal with a processing unit; and transmitting the command signal
using a broadband communication system to the downhole tool to
perform the task.
[0010] Further disclosed is an apparatus for controlling a task in
a borehole, the apparatus having: a downhole tool configured for
disposition into the borehole, the downhole tool also configured
for performing the task; a sensor in operable communication with an
aspect of the task; a controller in operable communication with the
downhole tool and the sensor, the controller configured to receive
a measurement from the sensor and to provide closed-loop control of
the downhole tool for controlling the task; and a broadband
communication system for coupling the sensor and the controller and
for coupling the controller and the downhole tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The subject matter, which is regarded as the invention, is
particularly pointed out and distinctly claimed in the claims at
the conclusion of the specification. The foregoing and other
features and advantages of the invention are apparent from the
following detailed description taken in conjunction with the
accompanying drawings, wherein like numbered elements are numbered
alike, in which:
[0012] FIG. 1 illustrates an exemplary embodiment of a drill string
with a downhole tool disposed in a borehole penetrating the
earth;
[0013] FIG. 2 illustrates aspects of a closed-loop control system
used for controlling the downhole tool; and
[0014] FIG. 3 presents one example of a method for performing a
task in the borehole.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Disclosed are techniques for causing a device (also referred
to as a "tool") to perform a task reliably and quickly downhole.
However, one skilled in the art will recognize that these
techniques are illustrative and not limiting of the teachings
herein. The techniques, which include systems and methods, make use
of a broadband communication system to transmit a command to the
device. The broadband communication system can also be used to
receive communications from the device, and to obtain data such as
from sensors and apparatus downhole. A decision that uses the data
or communications as input can be made by an operator and/or by a
processing unit. In some embodiments, decisions are made
automatically. Generally, the operator can use the processing unit
to input the command. The processing unit will quickly send a
command signal to the device upon input of the command. Upon
receipt of the command signal, the device will perform the
task.
[0016] For convenience, certain definitions are presented for use
throughout the specification. The term "drill string" relates to at
least one of drill pipe and a bottom hole assembly. In general, the
drill string includes a combination of the drill pipe and the
bottom hole assembly. The drill string assembly can also include
sensing or acting devices distributed along the drill pipe. The
bottom hole assembly may be a drill bit, sampling apparatus,
logging apparatus, or other apparatus for performing other
functions downhole. As one example, the bottom hole assembly can be
a drill collar containing measurement while drilling (MWD)
apparatus.
[0017] The term "actuation" relates to causing a mechanical action
or motion. The term "activation" relates to making something active
such as causing a sensor to perform a measurement. The term
"energization" relates providing power to something. The term
"de-energization" relates to removing power from something. The
term "performing a task" relates to using a device that requires at
least one of actuation, activation, energization, and
de-energization for performing the task. The term "command signal"
relates to a signal that causes a downhole device to perform a
task.
[0018] The term "real time" relates to a time period for
communication between a downhole apparatus and a processing unit
generally disposed remote from the downhole apparatus. The time
period is short enough for the downhole apparatus to perform a task
within an operational deadline consistent with a process proceeding
at a prescribed rate. The downhole apparatus can include sensors
and other devices used to perform the task downhole such as
diverting a flow of mud in the drill string. The time period for
real time communication is generally shorter than other time
periods related to the task. For example, if a task requires
several steps, then with real time communication, signals will be
received and/or transmitted in a time period shorter than at least
the time period of one step of the task and, preferably in a time
period shorter than each of the steps of the task. For embodiments
in which the processing unit is a controller in a closed-loop
control system, real-time communication is fast enough to prevent
the closed-loop from being unstable. As used herein, transmission
of signals in "real-time" is taken to mean transmission of the
signals at a speed that is useful or adequate for performing a task
downhole. Accordingly, it should be recognized that "real-time" is
to be taken in context, and does not necessarily indicate the
instantaneous determination of measurements or instantaneous
initiation of performing a task.
[0019] The term "broadband communication system" relates to a
communication system that is used to communicate signals at least
one of from downhole to the surface and from the surface to
downhole in real time. The signals can include a command, a control
signal or data. In some embodiments, the broadband communication
system can transmit and receive signals that are digitally encoded.
In some of these embodiments, portions of the digitally encoded
signal may be sent in pieces or packets to improve reliability
and/or the data transfer rate. One skilled in the art will
recognize that the broadband communication system does not include
mud-pulse telemetry or other telemetry systems with similar
speed.
[0020] The term "stable control" relates to preventing undamped
oscillations or an unwanted result of a function, task, or
parameter being controlled by a closed-loop control system.
[0021] FIG. 1 illustrates an exemplary embodiment of a drill string
10 disposed in a borehole 2 penetrating the earth 9. The drill
string 10 includes drill pipes 3 and a bottom hole assembly 4. The
bottom hole assembly 4 includes a downhole tool 5, which performs a
task 16. Referring to FIG. 1, a broadband communication system 6
transmits a command signal 7 from the processing unit 8 to the
downhole tool 5. Upon receiving the command signal 7, the downhole
tool 5 performs the task 16. It is recognized that some tasks 16
may require a time delay and that receipt of the command signal 7
provides for initiation of the time delay. Any required time delays
are considered within the scope of the task. The command signal 7
can also represent data being transmitted to apparatus
downhole.
[0022] Referring to FIG. 1, a sensor 19 is shown disposed on the
drill string 10 downhole. The sensor 19 can provide a measurement
of a property or parameter and transmit the measurement uphole as
data 11 to the processing unit 8. The sensor 19 can also represent
any device that sends information via the data 11 from downhole to
the processing unit 8. For example, the sensor 19 can represent a
local processor that performs a diagnostic check of the downhole
tool 5. The sensor 19 transmits the data 11 using the broadband
communication system 6. Thus, in one embodiment, the broadband
communication system 6 can provide two-way communications (both
uplink to the surface of the earth 9 and downlink to the downhole
tool 5).
[0023] Turning now to the broadband communication system 6, the
broadband communication system 6 provides for transmission of the
command signal 7 and the data 11 in real time. The broadband
communication system 6 can be implemented using any communication
method that can provide real time communication. Examples of the
method include acoustic transmission through the drill string 10,
low frequency radio waves traveling through the borehole 2 or the
earth 9, light waves transmitted in an optical fiber, and,
preferably, "wired pipe."
[0024] In one embodiment of wired pipe, the drill pipe 3 is
modified to include a broadband cable protected by a reinforced
steel casing. At the end of each drill pipe 3, there is an
inductive coil, which contributes to communication between two
drill pipes 3. In this embodiment, the broadband cable is used to
transmit the command signal 7 and the data 11. About every 500
meters, a signal amplifier is disposed in operable communication
with the broadband cable to amplify the communication signal to
account for signal loss.
[0025] One example of wired pipe is INTELLIPIPE.RTM. commercially
available from Intellipipe of Provo, Utah, a division of Grant
Prideco. One example of the broadband communication system 6 using
wired pipe is the INTELLISERV.RTM. NETWORK also available from
Grant Prideco. The Intelliserv Network has data transfer rates from
fifty-seven thousand bits per second to one million bits per second
or more. The broadband communication system 6 enables sampling
rates of the sensor 19 at up to 200 Hz or higher with each sample
being transmitted to the processing unit 8 at a location remote
from the sensor 19.
[0026] In the embodiment of FIG. 1, the drill pipe 3 and the
downhole tool 5 include electrical transmission conductors 14 for
transmitting the command signal 7 and the data 11.
[0027] Turning now to the processing unit 8, the processing unit 8
may include a computer processing system. Exemplary components of
the computer processing system include, without limitation, at
least one processor, storage, memory, input devices (such as a
keyboard and mouse), output devices (such as a display and a
recording device) and the like. As these components are known to
those skilled in the art, these are not depicted in any detail
herein.
[0028] Generally, some of the teachings herein are reduced to an
algorithm 12, shown in FIG. 1 that is stored on machine-readable
media. The algorithm 12 is implemented by the processing unit 8 and
provides operators with desired output.
[0029] Turning now to the downhole tool 5, examples of the downhole
tool 5 include a flow diverter, an underreamer, a whip stock, a
disconnect, a perforating device, and a casing placement and
expansion device. The flow diverter is a device, included in the
drill string 10, that comprises a flow path that can be opened or
closed upon receipt of the command signal 7. An opened flow path
diverts a flow of mud from the interior of the drill pipe 3 to the
annulus surrounding the drill string 10. The underreamer is a
device for increasing the diameter of the borehole 2 after the
borehole 2 was drilled using a drill bit. The underreamer includes
a cutter that can be extended from the drill string 10 upon receipt
of the command signal 7. The whipstock is a device for diverting a
drilling path of a drill bit in the borehole 2. In one embodiment,
an angle of the drill path can be set remotely. The whip stock upon
receipt of the command signal 7 will set an angle in accordance
with the angle information contained in the command signal 7. The
disconnect is a device that is used to attach an item to the drill
string 10. Upon receipt of the command signal 7, the disconnect
will release the item from the drill string 10. For example, the
disconnect may be used to attach the bottom hole assembly 4 to the
drill pipe 3. If the bottom hole assembly 4 becomes irretrievably
restrained in the borehole 2, then the disconnect can be used to
disconnect the bottom hole assembly 4 and, therefore, allow the
drill pipe 3 to be removed from the borehole 2. The perforating
device is an apparatus used for creating a hole in a casing or
liner of the borehole 2. The perforating device generally uses a
shaped explosive charge to create the hole. Upon receipt of the
command signal 7, the perforating device will trigger an explosion
of the charge to create the hole.
[0030] FIG. 2 illustrates aspects of a closed-loop control system
20 used for controlling the task 16 downhole. Referring to FIG. 2,
the closed-loop control system 20 includes the processing unit 8
for use as a controller (controller 8), the sensor 19 for measuring
some aspect related to the task 16, the downhole tool 5 for
performing the task 16, and the broadband communication system 6
for transmitting the data 11 from the sensor 19 to the controller 8
and for transmitting the command signal 7 from the controller 8 to
the bottom hole assembly 4. The command signal 7 can be a control
signal for providing closed-loop control of the task 16.
[0031] In the embodiment of FIG. 2, at least one of the data 11 and
the command signal 7 may be a continuous signal. Alternatively, at
least one of the data 11 and the command signal 7 may include
discrete digital signals. Generally, the discrete digital signals
are derived using a sampling rate high enough to provide stable
control of the task 16. The high data transfer rate of the
broadband communication system 6 also provides stable control of
the task 16.
[0032] In some embodiments of the closed-loop control system 20,
the controller 8 is configured to receive manual input from an
operator. The manual input may allow the operator to intervene in
controlling the task 16.
[0033] FIG. 3 presents one example of a method 30 for performing
the task 16 in the borehole 2. The method 30 calls for (step 31)
placing the downhole tool 5 in the borehole 2. Further, the method
30 calls for (step 32) initiating the command signal 7 using the
processing unit 8. Further, the method 30 calls for (step 33)
transmitting the command signal 7 using the broadband communication
system 6 to the downhole tool 5 to perform the task 16.
[0034] In support of the teachings herein, various analysis
components may be used, including digital and/or an analog systems.
The processing unit 8 and the downhole tool 5 may include the
digital and/or analog systems for example. The system may have
components such as a processor, storage media, memory, input,
output, communication link (wired, wireless, optical or other),
user interfaces, software programs, signal processors (digital or
analog) and other such components (such as resistors, capacitors,
inductors and others) to provide for operation and analyses of the
apparatus and methods disclosed herein in any of several manners
well-appreciated in the art. It is considered that these teachings
may be, but need not be, implemented in conjunction with a set of
computer executable instructions stored on a computer readable
medium, including memory (ROMs, RAMs), optical (CD-ROMs), or
magnetic (disks, hard drives), or any other type that when executed
causes a computer to implement the method of the present invention.
These instructions may provide for equipment operation, control,
data collection and analysis and other functions deemed relevant by
a system designer, owner, user or other such personnel, in addition
to the functions described in this disclosure.
[0035] Further, various other components may be included and called
upon for providing for aspects of the teachings herein. For
example, a sample line, sample storage, sample chamber, sample
exhaust, pump, piston, power supply (e.g., at least one of a
generator, a remote supply and a battery), vacuum supply, pressure
supply, cooling component, heating component, motive force (such as
a translational force, propulsional force or a rotational force),
magnet, electromagnet, sensor, electrode, transmitter, receiver,
transceiver, antenna, controller, optical unit, electrical unit or
electromechanical unit may be included in support of the various
aspects discussed herein or in support of other functions beyond
this disclosure.
[0036] Elements of the embodiments have been introduced with either
the articles "a" or "an." The articles are intended to mean that
there are one or more of the elements. The terms "including" and
"having" are intended to be inclusive such that there may be
additional elements other than the elements listed. The term "or"
when used with a list of at least two elements is intended to mean
any element or combination of elements.
[0037] One skilled in the art will recognize that the various
components or technologies may provide certain necessary or
beneficial functionality or features. Accordingly, these functions
and features as may be needed in support of the appended claims and
variations thereof, are recognized as being inherently included as
a part of the teachings herein and a part of the invention
disclosed.
[0038] While the invention has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications will be
appreciated by those skilled in the art to adapt a particular
instrument, situation or material to the teachings of the invention
without departing from the essential scope thereof. Therefore, it
is intended that the invention not be limited to the particular
embodiment disclosed as the best mode contemplated for carrying out
this invention, but that the invention will include all embodiments
falling within the scope of the appended claims.
* * * * *