U.S. patent application number 13/296755 was filed with the patent office on 2013-05-16 for wellbore condition monitoring sensors.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. The applicant listed for this patent is Sunil KUMAR. Invention is credited to Sunil KUMAR.
Application Number | 20130118733 13/296755 |
Document ID | / |
Family ID | 48279513 |
Filed Date | 2013-05-16 |
United States Patent
Application |
20130118733 |
Kind Code |
A1 |
KUMAR; Sunil |
May 16, 2013 |
WELLBORE CONDITION MONITORING SENSORS
Abstract
Disclosed is an apparatus for estimating a downhole property of
interest. The apparatus includes a carrier configured to be
conveyed in a borehole penetrating an earth formation and carry a
releasable sensor. The sensor is configured to be released by the
carrier into drilling fluid and to sense the property. The sensor
includes a memory to store sensed property data. The data can be
downloaded from the memory wirelessly with the sensor in the
drilling fluid or by retrieving the sensor from the drilling
fluid.
Inventors: |
KUMAR; Sunil; (Celle,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KUMAR; Sunil |
Celle |
|
DE |
|
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
48279513 |
Appl. No.: |
13/296755 |
Filed: |
November 15, 2011 |
Current U.S.
Class: |
166/254.2 ;
166/66 |
Current CPC
Class: |
E21B 47/26 20200501;
E21B 41/0085 20130101 |
Class at
Publication: |
166/254.2 ;
166/66 |
International
Class: |
E21B 47/00 20120101
E21B047/00 |
Claims
1. An apparatus for estimating a downhole property of interest, the
apparatus comprising: a carrier configured to be conveyed in a
borehole penetrating an earth formation and carry a releasable
sensor; and a sensor configured to be released by the carrier into
drilling fluid and to sense the property; wherein the sensor
comprises a memory to store sensed property data.
2. The apparatus according to claim 1, wherein the carrier is
configured to release the sensor external to the carrier and into
the borehole where the sensor travels uphole in the drilling
fluid.
3. The apparatus according to claim 1, where the carrier is
configured to release the sensor internal to the carrier where the
sensor exits a drill bit into the borehole where the sensor travels
uphole in the drilling fluid.
4. The apparatus according to claim 1, further comprising a
receiving device configured to receive the sensor from the borehole
fluid or the sensed memory data from the sensor that has been
released from the carrier.
5. The apparatus according to claim 4, wherein the receiving device
comprises a screen configured to entrap the sensor.
6. The apparatus according to claim 4, wherein the receiving device
comprises a magnet configured to attract the sensor in the borehole
fluid.
7. The apparatus according to claim 4, wherein the receiving device
comprises a first transducer configured to receive signals from the
sensor.
8. The apparatus according to claim 7, wherein the first transducer
comprises an antenna and the signals are electromagnetic
signal.
9. The apparatus according to claim 7, wherein the sensor further
comprises a second transducer configured to transmit the signals to
the receiving device in order to transmit the sensed property
data.
10. The apparatus according to claim 9, wherein the second
transducer comprises an antenna and the signals are electromagnetic
signals.
11. The apparatus according to claim 9, wherein the sensor further
comprises a transmitter configured to transmit the sensed property
data using the second transducer.
12. The apparatus according to claim 9, wherein the second
transducer is configured to transmit acoustic, magnetic or optical
signals.
13. The apparatus according to claim 4, the sensor comprising a
connector configured to receive data from the carrier or download
data to the receiving device.
14. The apparatus according to claim 4, wherein the sensor
comprises a beacon configured to emit a signal to activate or
deactivate the receiving device.
15. The apparatus according to claim 1, wherein the sensor is
encapsulated in a protective coating.
16. The apparatus according to claim 1, wherein the sensor
comprises a thermocouple configured to measure temperature.
17. The apparatus according to claim 1, wherein the sensor
comprises a flexural mechanical resonator configured to measure a
property of a downhole fluid.
18. The apparatus according to claim 17, wherein the flexural
mechanical resonator comprises a plurality of flexural mechanical
resonators with each resonator tuned to a specific range of
measurements.
19. The apparatus according to claim 1, wherein the sensor
comprises a processor configured to operate the sensor to obtain
the sensed property data and to store the sensed property data in
the memory.
20. The apparatus according to claim 19, wherein the processor
comprises a clock configured to provide a time at which each
measurement is performed.
21. The apparatus according to claim 1, wherein the sensor
comprises a power source configured to power the sensor.
22. The apparatus according to claim 1, wherein the sensor
comprises a pressure transducer configured to measure depth in the
borehole at which each measurement is performed.
23. The apparatus according to claim 1, wherein the sensor is
configured to sense at least one of temperature, pressure, density,
viscosity, compressibility, acoustic property, magnetic property,
chemical composition and material characteristic of the formation,
fluid in the formation, drill string components, and drilling
fluid.
24. The apparatus according to claim 1, wherein the carrier is
conveyed by a drill string or coiled tubing.
25. A method for estimating a downhole property of interest, the
method comprising: conveying a carrier through a borehole
penetrating the earth; releasing a sensor into drilling fluid;
sensing the property of interest using the sensor; and downloading
data sensed by the sensor at a location uphole from the
sensing.
26. The method according to claim 25, wherein downloading comprises
retrieving the sensor from the drilling fluid or receiving
transmitted sensed data from the sensor.
27. The method according to claim 25, wherein the sensing is
performed before the releasing.
28. The method according to claim 25, wherein the sensor comprises
a plurality of sensors.
29. The method according to claim 28, wherein two or more sensors
in the plurality are configured to sense a same property.
Description
BACKGROUND
[0001] In wellbore operations, the condition of a wellbore, a
downhole tool, a reservoir, or fluid in the wellbore is typically
measured by sensors in proximity to the drill bit and transmitted
to the surface of the earth by a downhole telemetry system.
Alternatively, the condition information is stored in memory
disposed in a downhole tool and accessed by downloading the data
upon retrieval of the tool from the wellbore. While a downhole
telemetry system can transmit sensor data generally continuously,
the overall transmission of data may be slow due to limited
bandwidth. Similarly, while downloading data from a retrieved
downhole tool may be performed with high bandwidth transmission, it
can take from a few hours to days in order to retrieve the tool.
Both methods may be ultimately too slow when downhole conditions
are rapidly changing. Hence, it would be appreciated in the
drilling industry if data obtained from downhole sensors could be
provided to drilling operators in a timely manner.
BRIEF SUMMARY
[0002] Disclosed is an apparatus for estimating a downhole property
of interest. The apparatus includes a carrier configured to be
conveyed in a borehole penetrating an earth formation and carry a
releasable sensor. The sensor is configured to be released by the
carrier into drilling fluid and to sense the property. The sensor
includes a memory to store sensed property data.
[0003] Also disclosed is a method for estimating a downhole
property of interest. The method includes: conveying a carrier
through a borehole penetrating the earth; releasing a sensor into
drilling fluid; sensing the property of interest using the sensor;
and downloading data sensed by the sensor at a location uphole from
the sensing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0005] FIG. 1 illustrates an exemplary embodiment of a downhole
tool having a plurality of releasable sensors disposed in a
borehole penetrating the earth;
[0006] FIG. 2 depicts aspects of a sensor release mechanism for
releasing sensors from the downhole tool into the borehole;
[0007] FIG. 3 depicts aspects of one embodiment of a sensor for
measuring temperature;
[0008] FIG. 4 depicts aspects of one embodiment of a sensing
element having a flexural mechanical resonator for characterizing a
downhole fluid;
[0009] FIG. 5 depicts aspects of one embodiment of a sensing
element using photons for sensing a downhole property of
interest;
[0010] FIG. 6 depicts aspects of one embodiment of a sensing
element using acoustic signals for sensing a downhole property of
interest; and
[0011] FIG. 7 presents one example of a method for estimating a
downhole property of interest.
DETAILED DESCRIPTION
[0012] A detailed description of one or more embodiments of the
disclosed apparatus and method presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0013] FIG. 1 illustrates an exemplary embodiment of a drill string
5 disposed in a borehole 2 penetrating the earth 3, which includes
a formation 4. The formation 4 represents any downhole material of
interest. A drill string rotation system 12 disposed at a drill rig
11 at the surface of the earth 3 is configured to rotate the drill
string 5 in order to rotate a drill bit 6 disposed at a distal end
of the drill string 5. The drill bit 6 represents any cutting
device configured to cut through the earth 3 or rock in the
formation 4 in order to drill the borehole 2. Disposed adjacent to
the drill bit 6 is a bottom hole assembly (BHA) 7. The drill bit 6
can be included in the BHA 7 or it can be separate from it. The BHA
7 can include downhole components such as a downhole tool 10 and a
mud motor (not shown). In order to cool and lubricate the drill bit
6 and flush cuttings from the borehole 2, drilling fluid 8 is
pumped downhole through the interior of the drill string 5 from
which it exits the drill bit 6. The drilling fluid 8 then returns
to the drill rig 11 via an annulus 13 surrounding the BHA 7 and the
drill string 5 within the borehole 2.
[0014] Still referring to FIG. 1, a plurality of sensors 9 is
disposed at the downhole tool 10. Each of the sensors 9 is
configured to sense (i.e., measure) a property of interest. The
downhole tool 10 is configured to release one or more of the
sensors 9 into the annulus 13 by one of two pathways. In a first
pathway, one or more of the sensors 9 is released external to the
downhole tool 10 and BHA 7 into the annulus 13. In a second
pathway, one or more of the sensors 9 is released internal to the
downhole tool 10 and BHA 7 into an internal conduit 14 conveying
the drilling fluid 13 to the drill bit 6. Hence, in the second
pathway, one or more of the sensors 9 is released into the annulus
13 after traversing the drill bit 6.
[0015] After a sensor 9 is released, it can perform one or more
measurements of a property of interest. Non-limiting examples of
the property of interest include temperature, pressure, density,
viscosity, compressibility, acoustic property, magnetic property,
chemical composition and material characteristic of the formation,
fluid in the formation, drill string components, and drilling
fluid. Applications using the sensed property of interest include
detection of corrosion, scaling, asphaltenes and waxes. The
property of interest can be an ambient condition (e.g., temperature
or pressure) experienced by the sensor 9 or a characteristic of a
downhole material such as the formation or formation fluid at the
borehole 2. Measurement data is generally stored in a memory in the
sensor 9.
[0016] Sensors 9 that are released travel uphole (i.e., up the
borehole from the downhole tool 10 towards the surface of the
earth) in the annulus 13 towards the surface of the earth 3. In one
or more embodiments, the sensors 9 are buoyant in the drilling
fluid 13 and thus are able to float in the drilling fluid 13 to the
surface of the earth 3. Alternatively, or in addition to buoyancy,
the sensor 9 may also contain a mechanism to power the sensor 9 to
the surface. Non-limiting embodiments of the mechanism include
piezo-actuated flappers, tails, or propellers powered by battery or
energy harvesters, which in one or more embodiments can harvest
energy from the drilling fluid flow, vibration, or temperature
differentials.
[0017] In one or more embodiments, upon reaching the surface of the
earth 3, the released sensors 9 are retrieved from the drilling
fluid 13 by a receiving device such as a sieve or screen 15. After
a released sensor 9 is retrieved, the stored measurement data can
be downloaded from the sensor 9 either at the well site or offsite
in a laboratory.
[0018] In one or more embodiments, the stored measurement data from
a released sensor 9 is received by the receiving device as radio
frequency (RF) energy via a receiver 16 and a hoop antenna 17 at
the surface while the sensor 9 is still immersed in the drilling
fluid 8. Alternatively, or in combination, the receiver 16 can
represent a receiver and a transducer configured to receive
magnetic, acoustic or optical signals.
[0019] In one or more embodiments, the sensors 9 can be
interrogated and then reset to store multiple layers of information
through different runs where they can run or circulate continuously
with the drilling fluid without being filtered out of the drilling
fluid. As circulating sensors, these sensors 9 can act as drilling
fluid monitors, monitoring properties of the drilling fluid
throughout a drilling run.
[0020] Reference may now be had to FIG. 2 depicting aspects of a
sensor release mechanism 20 configured to release one or more of
sensors 9 from the downhole tool 10. The sensor release mechanism
20 includes a rack 21 for holding and securing the plurality of
sensors 9 in the downhole tool 10. The sensor release mechanism 20
also includes an ejector 22 coupled to a controller 23 and
configured to eject each of sensors 9 from the downhole tool 10. A
detachable connector 24 couples each of the sensors 9 to the
controller 23, which can issue download information to each of the
sensors 9. The downloaded information can include commands to
activate each sensor 9 to commence performing measurements upon
ejection or after a time delay. The download information can also
include other information such as the present time and/or depth
when each sensor 9 is released. It can be appreciated that the
controller 23 can also be configured to download measurement data
from other downhole tools disposed at the BHA 7 to a memory in one
or more of the sensors 9. It can be appreciated that the
downloading of measurement data from other downhole tools to the
sensors 9 can provide a redundant method of transmitting data from
the other downhole tools to the surface of the earth. Similarly, it
can be appreciated that multiple sensors 9 having the same
information can provide redundancy in the system such that missing
or damaged sensors 9 will not cause a loss of data.
[0021] Still referring to FIG. 2, the controller 23 is coupled to
door actuators 25 and 26 and configured to operate doors 27 and 28,
respectively. The doors 27 and 28 are configured to allow the
drilling fluid 8 to enter and exit the downhole tool 10 in order to
provide the first pathway leading to the annulus 13. It can be
appreciated that the doors 27 and 28 can be hinged doors, sliding
doors or a combination thereof appropriate for downhole use.
Alternatively, another door or doors in addition to or instead of
the doors 27 and 28 may be configured to provide access to the
internal conduit 14.
[0022] Reference may now be had to FIG. 3 depicting aspects of one
sensor 9 in the plurality of sensors 9. The sensor 9 includes a
sensing element 30 coupled to a processing unit 31, both disposed
on substrate 32, which can include connections between various
components. The sensing element 30 is configured to interact with
the property of interest being sensed. In the embodiment of FIG. 3,
the sensing element 30 is a thermocouple 33 configured to sense
temperature. The processing unit 31 is configured to process
signals received from the sensing element 30 in order to measure
the property of interest and store sensed measurement data for
later retrieval. The processing unit 31 can include a clock
configured to provide a time at which each measurement is performed
by the sensor 9. The processing unit 31 includes memory 34 for
storing the sensed measurement data and a download interface 35 for
downloading the stored sensed measurement data. In non-limiting
embodiments, the memory 34 can be a rewritable memory or a one-time
set memory. In one or more embodiments, the download interface 35
includes a connector 36. The connector 36 can also be used as a
power receptacle to receive power from the downhole tool 10 such as
for recharging a power source. In one or more embodiments, the
download interface 35 includes a transmitter 37 coupled to an
antenna 38 for transmitting the stored sensed measurement data to
the receiver 16 via the antenna 17. In one or more embodiments, the
transmitter 37 in the download interface 35 can represent a
transceiver and transducer configured transmit or receive radio
frequency (RF), acoustic, or magnetic signals for data or power
transfer. A power source 45 is disposed on the substrate 32 and is
configured to supply electrical power to the processing unit 31
and/or the sensing element 30. The power source 45 can include
batteries (disposable or rechargeable), supercapacitors, or energy
harvesting mechanisms that can harvest energy from drilling fluid
flow, vibrations, or temperature differentials besides other
processes. A buoyancy device 39 if needed is coupled to the
substrate 32 in order to insure that the sensor 9 floats in the
drilling fluid 8. In one or more embodiments, components of the
sensor 9 are integrated into one or more integrated circuits. In
one or more embodiments, the sensor 9 is built as a
micro-electromechanical system (MEMS) or nano-electromechanical
system (NEMS) in order for the sensor 9 to be small enough to
travel unimpeded in the drilling fluid 8.
[0023] Still referring to FIG. 3, the sensor 9 can include a
signal-emitting beacon 43 configured to act as a transmitter to
engage the sieve or screen 15 or capture mechanism such as an
electromagnetic trap. The beacon 43 can be used by the capture
mechanism or trap at the surface to locate the sensor 9, engage the
trap, recover the sensor 9 and then release the trap. A moving or
varying beacon 43 can signal a still uncaptured sensor 9 while a
static signal strength can signal that a sensor 9 is captured in
the trap.
[0024] Reference may now be had to FIG. 4 depicting aspects of
another embodiment of the sensing element 30. In the embodiment of
FIG. 4, the sensing element 30 includes a plurality of flexural
mechanical resonators 40 configured to be immersed in a liquid of
interest in order to sense a physical property such as density or
viscosity of the liquid of interest. In one or more embodiments,
each flexural mechanical resonator 40 is made of a piezoelectric
material embedded with one or more electrodes. An electric field
applied by the one or more electrodes causes the piezoelectric
material to resonate in the liquid of interest. The resonating or
motion of the resonator in the liquid of interest provides an
electrical impedance (also called fluid motion impedance) as
measured via the one or more electrodes that is related to a
physical property of the liquid of interest. Each flexural
mechanical resonator 40 in the plurality is configured to measure a
physical property in a selected range of values such that the
plurality of flexural mechanical resonators 40 can measure that
physical property over a wide range of values that encompasses the
selected ranges of values. Alternatively, each flexural mechanical
resonator 40 can be tuned to detect a specific chemical(s) or a
property of that chemical(s).
[0025] Reference may now be had to FIG. 5 depicting aspects of
another embodiment of the sensing element 31. In the embodiment of
FIG. 5, the sensing element 30 includes a light source 50 and a
photodetector 51. The light source 50 is configured to generate or
emit light onto a material of interest such as a wall of the
borehole 2. The light detector 51 is configured to detect the
emitted light that is reflected from the material of interest in
order to sense or measure a property of the material of interest.
Alternatively, the photodetector 51 can be configured to detect
light traversing the material of interest in order to sense or
measure the property. It can be appreciated that in one or more
embodiments the sensing element 31 depicted in FIG. 5 can be
configured for reflective or transmissive spectroscopy.
[0026] Reference may now be had to FIG. 6 depicting aspects of
another embodiment of the sensing element 30. In the embodiment of
FIG. 6, the sensing element includes one or more acoustic
transducers 60. Each acoustic transducer 60 is configured to
transmit and/or receive acoustic energy or signals. The acoustic
signals can propagate through or reflect from the drilling fluid,
the formation, formation fluid, and/or the BHA in order to
characterize those entities.
[0027] It can be appreciated that the sensors 9 can be used to
detect a condition of the drill bit 6 when the sensors 9 are
released into the internal conduit 14. In one or more non-limiting
embodiments, the sensors 9 can be used to detect a condition or
property of the drilling fluid 8, formation fluid disposed in the
borehole 2, the formation 4 at a wall of the borehole 2, or the BHA
7. It can be appreciated that the use the plurality of sensors 9
provides for multiple measurements of the same property of
interest, which can be combined or averaged to provide a
measurement having increased accuracy or precision versus a single
measurement by a single sensor 9. In addition, measurements
obtained by the sensors 9 can be stacked over a period of time.
[0028] It can be appreciated that hundreds of the sensors 9 can be
fabricated at low cost using semiconductor fabrication technology
and that hundreds of the sensors 9 may be deployed during a
drilling operation where the downhole tool 10 is not removed from
the borehole 2. It can be appreciated that when a plurality of the
sensors 9 is released into the borehole 2, the sensors 9 can be
configured to be self-actuating upon detection of the drilling
fluid 8 electrically or optically as non-limiting examples.
[0029] It can be appreciated that the sensor 9 can be made on
silicon, glass, ceramic, metal, polymer, plastic and other
substrates using conventional and semiconductor
processing/fabrication methods not limited to CMOS batch
fabrication, ink printing, screen printing, embossing and other
methods known in the art. In one or more embodiments, the sensor 9
can be built on a tape such as a polyimide tape. In one or more
embodiments, the sensor 9 can be encapsulated in hard abrasion
resistant materials such as ceramics and/or in hard high
temperature capable polymers such as PEEK to avoid physical damage
to sensor components.
[0030] FIG. 7 presents one example of a method 70 for estimating a
downhole property of interest. The method 70 calls for (step 71)
conveying a carrier through a borehole penetrating the earth.
Further, the method 70 calls for (step 72) releasing a sensor from
the carrier into drilling fluid in the borehole. One or more
sensors 9 can be released while the BHA is being inserted into the
borehole, during drilling, or while the drill stem is static in the
borehole. Further, the method 70 calls for (step 73) sensing the
property of interest using the sensor. The sensed property
measurement(s) can be stored in a memory for later downloading.
Further, the method 70 calls for (step 74) downloading data from
the sensor at a location uphole from the sensing.
[0031] In support of the teachings herein, various analysis
components may be used, including a digital and/or an analog
system. For example, the downhole electronics 11, the surface
computer processing 12, or the processing unit 31 may include the
digital and/or analog system. The system may have components such
as a processor, storage media, memory, input, output,
communications link (wired, wireless, pulsed mud, 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
non-transitory 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.
[0032] Further, various other components may be included and called
upon for providing for aspects of the teachings herein. For
example, a power supply (e.g., at least one of a generator, a
remote supply and a battery), cooling component, heating component,
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.
[0033] The term "carrier" as used herein means any device, device
component, combination of devices, media and/or member that may be
used to convey, house, support or otherwise facilitate the use of
another device, device component, combination of devices, media
and/or member. Other exemplary non-limiting carriers include drill
strings of the coiled tube type, of the jointed pipe type and any
combination or portion thereof. Other carrier examples include
casing pipes, wirelines, wireline sondes, slickline sondes, drop
shots, bottom-hole-assemblies, drill string inserts, modules,
internal housings and substrate portions thereof.
[0034] 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 conjunction
"or" when used with a list of at least two terms is intended to
mean any term or combination of terms. The terms "first" and
"second" are used to distinguish elements and are not used to
denote a particular order. The term "couple" relates to coupling a
first component to a second component either directly or indirectly
through an intermediate component.
[0035] It will be recognized 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.
[0036] While the invention has been described with reference to
exemplary embodiments, it will be understood 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 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.
* * * * *