U.S. patent application number 14/522167 was filed with the patent office on 2016-04-28 for wireless retrievable intelligent downhole production module.
This patent application is currently assigned to BAKER HUGHES INCORPORATED. The applicant listed for this patent is Ignacio Martinez. Invention is credited to Ignacio Martinez.
Application Number | 20160115782 14/522167 |
Document ID | / |
Family ID | 55791590 |
Filed Date | 2016-04-28 |
United States Patent
Application |
20160115782 |
Kind Code |
A1 |
Martinez; Ignacio |
April 28, 2016 |
WIRELESS RETRIEVABLE INTELLIGENT DOWNHOLE PRODUCTION MODULE
Abstract
An apparatus for performing an operation in a borehole
penetrating the earth includes a downhole module configured to
perform the operation and having an anchor device configured to
anchor the module in the borehole, the anchor device being
releasable in order to retrieve the module. A power source is
disposed on the module and configured to provide power to the
module while a signal transducer is disposed on the module and
configured to at least one of transmit a wireless signal and
receive a wireless signal. The apparatus further includes a
downhole electronic device disposed on the module, coupled to the
signal transducer, and configured to operate the module and provide
communications to the module including repeating a signal for
transmission downhole or uphole.
Inventors: |
Martinez; Ignacio; (Rio de
Janeiro, BR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Martinez; Ignacio |
Rio de Janeiro |
|
BR |
|
|
Assignee: |
BAKER HUGHES INCORPORATED
Houston
TX
|
Family ID: |
55791590 |
Appl. No.: |
14/522167 |
Filed: |
October 23, 2014 |
Current U.S.
Class: |
340/853.3 |
Current CPC
Class: |
E21B 47/12 20130101;
E21B 41/0085 20130101 |
International
Class: |
E21B 47/12 20060101
E21B047/12 |
Claims
1. An apparatus for performing an operation in a borehole
penetrating the earth, the apparatus comprising: a downhole module
configured to perform the operation and comprising an anchor device
configured to anchor the module in the borehole, the anchor device
being releasable in order to retrieve the module; a power source
disposed on the module and configured to provide power to the
module; a signal transducer disposed on the module and configured
to at least one of transmit a wireless signal and receive a
wireless signal; and a downhole electronic device disposed on the
module, coupled to the signal transducer, and configured to operate
the module and provide communications to the module including
repeating a signal for transmission downhole or uphole.
2. The apparatus according to claim 1, wherein the wireless signal
is an electromagnetic signal, an acoustic signal, or some
combination thereof.
3. The apparatus according to claim 2, wherein the signal
transducer is an antenna, an acoustic transducer, or some
combination thereof.
4. The apparatus according to claim 1, further comprising a signal
receiver disposed at or near the surface of the earth and
configured to receive the wireless signal.
5. The apparatus according to claim 4, the signal receiver is
further configured to transmit the wireless signal to a controller
configured to send a control signal to the module.
6. The apparatus according to claim 1, wherein the power source
comprises a battery.
7. The apparatus according to claim 6, wherein the power source
comprises a turbine generator configured to convert energy from a
fluid flowing in the borehole into electrical energy to charge the
battery.
8. The apparatus according to claim 1, further comprising a flow
control valve coupled to the module and configured to receive a
control signal using the signal transducer from a controller and to
control flow through the valve based on the control signal.
9. The apparatus according to claim 8, wherein the controller is
disposed at the surface of the earth.
10. The apparatus according to claim 8, further comprising an
expandable seal configured to isolate the control valve from the
borehole annulus above or below the control valve.
11. The apparatus according to claim 10, wherein the expandable
seal comprises an upper expandable seal disposed above the flow
control valve and a lower expandable seal disposed below the flow
control valve.
12. The apparatus according to claim 8, wherein the flow control
valve is electromechanically actuated.
13. The apparatus according to claim 1, further comprising a sensor
coupled to the downhole electronics and configured to sense a
parameter, the downhole electronic device being configured to
transmit the wireless signal using the signal transducer, the
wireless signal comprising a sensor reading.
14. The apparatus according to claim 13, wherein the sensor is
configured to sense a flow rate of fluid flowing through the flow
control valve.
15. An apparatus for performing an operation in a borehole
penetrating the earth, the apparatus comprising: a downhole module
configured to perform the operation and comprising an anchor device
configured to anchor the module in the borehole, the anchor device
being releasable in order to retrieve the module; a power source
disposed on the module and configured to provide power to the
module, the power source comprising a battery; a signal transducer
disposed on the module and configured to at least one of transmit a
wireless signal and receive a wireless signal; a downhole
electronic device disposed on the module, coupled to the signal
transducer, and configured to operate the module and provide
communications to the module including repeating a signal for
transmission downhole or uphole; an electromechanically actuated
flow control valve coupled to the module and configured to receive
a control signal using the signal transducer from a controller and
to control flow through the valve based on the control signal; and
a sensor coupled to the downhole electronics and configured to
sense a parameter, the downhole electronic device being configured
to transmit the wireless signal using the signal transducer, the
wireless signal comprising a sensor reading.
16. A method for performing an operation in a borehole penetrating
the earth, the method comprising: disposing a downhole module in
the borehole, the module being configured to perform the operation
and comprising an anchor device configured to anchor the module in
the borehole and to be released in order to retrieve the module, a
power source disposed on the module and configured to provide power
to the module, a signal transducer disposed on the module and
configured to at least one of transmit a wireless signal and
receive a wireless signal, and a downhole electronic device
disposed on the module, coupled to the signal transducer, and
configured to operate the module and provide communications to the
module including repeating a received wireless signal for
transmission downhole or uphole; anchoring the module in the
borehole using the anchor device; and performing the operation
using the module.
17. The method according to claim 16, wherein the operation
comprises repeating a received wireless signal using the downhole
electronic device and the signal transducer.
18. The method according to claim 16, further comprising receiving
a wireless control signal from a controller disposed at the surface
of the earth and controlling a flow control valve coupled to the
module and configured to control flow through the valve based on
the control signal.
19. The method according to claim 18, further comprising modulating
the flow through the flow control valve to achieve a selected flow
rate using the control signal.
20. The method according to claim 16, further comprising sensing a
parameter with a sensor coupled to the module and transmitting a
wireless signal comprising the sensed parameter using the signal
transducer to a receiver disposed at or near the surface of the
earth.
21. The method according to claim 16, further comprising releasing
the anchor device and relocating the module.
Description
BACKGROUND
[0001] Hydrocarbons such as oil and gas are produced from
reservoirs contained in earth formations. Boreholes drilled into
the reservoirs are used to gain access to the hydrocarbons. Once a
borehole is drilled, it is usually lined with a casing that is
cemented in place, a screen or some other type of borehole liner.
The hydrocarbons are then extracted from a reservoir and then
flowed to the surface through the lined borehole.
[0002] Some formations may include multiple reservoirs or producing
zones (several producing zones may be from the same reservoir)
stacked one upon another. In these cases, one borehole may
penetrate two or more of the stacked reservoirs or producing zones.
Each reservoir or producing zone though may have different
production characteristics such as an amount of water that is
produced. In order to compensate for the different production
characteristics, the flow from each reservoir needs to be
controlled. Advancements in technology to improve flow control of
fluids from reservoirs or producing zones, educe intervention cost,
and improve flow efficiency would be well received in the drilling
industry.
BRIEF SUMMARY
[0003] Disclosed is an apparatus for performing an operation in a
borehole penetrating the earth. The apparatus includes: a downhole
module configured to perform the operation and having an anchor
device configured to anchor the module in the borehole, the anchor
device being releasable in order to retrieve the module; a power
source disposed on the module and configured to provide power to
the module; a signal transducer disposed on the module and
configured to at least one of transmit a wireless signal and
receive a wireless signal; and a downhole electronic device
disposed on the module, coupled to the signal transducer, and
configured to operate the module and provide communications to the
module including repeating a signal for transmission downhole or
uphole.
[0004] Also disclosed is an apparatus for performing an operation
in a borehole penetrating the earth includes: a downhole module
configured to perform the operation and having an anchor device
configured to anchor the module in the borehole, the anchor device
being releasable in order to retrieve the module; a power source
disposed on the module and configured to provide power to the
module, the power source comprising a battery; a signal transducer
disposed on the module and configured to at least one of transmit a
wireless signal and receive a wireless signal; a downhole
electronic device disposed on the module, coupled to the signal
transducer, and configured to operate the module and provide
communications to the module including repeating a signal for
transmission downhole or uphole; an electromechanically actuated
flow control valve coupled to the module and configured to receive
a control signal using the signal transducer from a controller and
to control flow through the valve based on the control signal; and
a sensor coupled to the downhole electronics and configured to
sense a parameter, the downhole electronic device being configured
to transmit the wireless signal using the signal transducer, the
wireless signal comprising a sensor reading.
[0005] Further disclosed is a method for performing an operation in
a borehole penetrating the earth includes: disposing a downhole
module in the borehole, the module being configured to perform the
operation and having an anchor device configured to anchor the
module in the borehole and to be released in order to retrieve the
module, a power source disposed on the module and configured to
provide power to the module, a signal transducer disposed on the
module and configured to at least one of transmit a wireless signal
and receive a wireless signal, and a downhole electronic device
disposed on the module, coupled to the signal transducer, and
configured to operate the module and provide communications to the
module including repeating a received wireless signal for
transmission downhole or uphole; anchoring the module in the
borehole using the anchor device; and performing the operation
using the module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0007] FIG. 1 illustrates a cross-sectional view of an exemplary
embodiment of downhole modules disposed in a borehole penetrating
the earth;
[0008] FIGS. 2A-2C, collectively referred to as FIG. 2, depict
aspects of the downhole modules;
[0009] FIG. 3 depicts aspects of a downhole module having a sensor;
and
[0010] FIG. 4 is a flow chart for a method for performing an
operation in a borehole penetrating the earth.
DETAILED DESCRIPTION
[0011] 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.
[0012] Disclosed are apparatus and method for performing an
operation or function in a borehole penetrating the earth. The
operation is implemented by a downhole module that is conveyed
through the borehole and anchored in the borehole at a specific
location. Operational functions include flow control of fluid
(e.g., performed by a valve operated remotely with several choke
positions) extracted from a formation and to be flowed to the
surface in the borehole and sensing one or more parameters such as
fluid flow rate, pressure, temperature, vibration, and/or fluid
characteristics. Additionally, the module includes communications
capability using wireless signals to receive a flow control signal
(e.g., to regulate percent of valve opened or completely close the
valve) and to transmit sensed parameters to the surface. The
communications capability includes providing repeater service to
relay received wireless signals from either an uphole location
(i.e., above the module) to a downhole location (i.e., below the
module) or from a downhole location to an uphole location.
[0013] FIG. 1 illustrates a cross-sectional view of three downhole
modules 10 disposed in a borehole 2 penetrating the earth 3
containing producing zones 4A and 4B. While FIG. 1 illustrates only
two producing zones for teaching purposes, the teachings can apply
to more than two producing zones with the additional zones being
equipped with a wireless intelligent production module. The
borehole 2 may be lined with a liner 5 such as a casing or screen
or the borehole 2 may be unlined (i.e., open hole configuration) as
non-limiting embodiments. Downhole module 10A is configured to be a
repeater module for relaying wireless signals, if needed, while
modules 10B and 10C are flow control modules configured to control
the flow of corresponding reservoir fluid into and up the borehole
2. Reservoir fluid may enter the borehole 2 through perforations in
a casing or screen if these liners are present.
[0014] Each module 10 may be conveyed through the borehole 2 by a
carrier 6 such as a wireline 7 having a module interface. Other
carriers may include segmented drill pipe or coiled tubing. Further
each module 10 includes a module anchor 8 that is configured to
anchor the module 10 to the liner 5 or directly to the borehole if
a liner in not present. To anchor the module 10, the module anchor
8 includes extendable anchor elements 9. The extendable anchor
elements 9 may be actuated by the carrier 6 using a mechanical
linkage or some other configuration. In addition, the extendable
anchor elements 9 may be retracted by the carrier 6 using the
mechanical linkage or other configurations in order to move the
module 10 to another location and or to remove the module 10 from
the borehole.
[0015] In order to power operations, each module 10 includes a
power source 13 that is configured to provide sufficient power to
power the operation of the corresponding module 10. In one or more
embodiments, the power source 13 includes a power accumulator 14
such as a battery or capacitor as non-limiting examples. In one or
more embodiments, the power source 13 includes a turbine generator
15 configured to convert energy of borehole fluid flowing through
the borehole to electrical energy that may be used to power module
operations or to charge the power accumulator 14. Alternatively, a
high capacity battery alone may be used to power the module
operations.
[0016] Each module 10 includes wireless communications capability
implemented by one or more signal transducers 11 and downhole
electronics 12. Each signal transducer 11 is configured to convert
an electrical signal to a wireless signal and/or a wireless signal
into an electrical signal. Non-limiting embodiments of wireless
signals include electromagnetic signals and acoustic signals.
Accordingly, embodiments of a signal transducer 11 include an
antenna and an acoustic transducer. In one or more embodiments,
each module 10 is configured to provide repeater service to relay
wireless signals to a nearby or adjacent module 10. In one or more
embodiments, a module 10 may be configured to have two-way
communications with a controller 16 disposed at the surface of the
earth. The controller 16 may be implemented by a computer
processing system as illustrated in FIG. 1. The controller 16
receives and transmits wireless signals using a surface signal
receiver 17 that is disposed at or near the surface of the earth.
The wireless signals may include a control signal for controlling
operation of one or more modules 10 or a data signal for
communicating data, such as sensor data or operational data,
transmitted by one or more of the modules 10.
[0017] As noted above, the module 10 may be configured to control
the flow of formation fluid into and up the borehole. As such, the
module 10 may include a flow control valve 19. The flow control
valve can be an open-close valve or a modulating valve that can
modulate the flow through the valve to obtain a selected flow rate
such as a percentage of the maximum flow capacity. The downhole
electronics 12 are configured to receive a control signal from the
controller 16 and to actuate the flow control valve based on the
information in the control signal. In one or more embodiments, the
flow control valve is actuated or operated by a solenoid for
electromechanical valve operation. Other types of actuation may
also be used.
[0018] When the module 10 includes the flow control valve 19, the
module 10 may also include an expandable seal 18. The expandable
seal 18 is configured to expand in order to seal against the
borehole 2 or the liner 5. When expanded, the seal 18 isolates the
borehole above the module 10 or the borehole below the module 10
from the borehole annulus surrounding the flow control valve 19.
Hence, the seal 18 or seals 18 are configured to direct reservoir
fluid flow from the reservoir into the flow control valve 19.
[0019] FIG. 2 depicts aspects of the downhole modules 10. FIG. 2A
illustrates the modules 10A-C disposed downhole with valve modules
10B and 10C being disposed in separate reservoirs. As illustrated
in FIG. 2B, the repeater module 10A includes an electronic
transceiver 21 configured for relaying the wireless signals. The
repeater module 10A also includes a battery 22 in the power
accumulator 14. As illustrated in
[0020] FIG. 2C, the valve modules 10B and 10C include an
electromechanically actuated flow control valve 23. The
electrically actuated flow control valve is configured to use power
from the power source 13 to actuate the valve 23 according to
information received from a wireless control signal that was
transmitted by the controller 16.
[0021] FIG. 3 depicts aspects of a downhole module 10 having a
sensor 30. The sensor 30 may be disposed on the repeater module 10A
and/or the valve module 10B or 10C. Alternatively, the sensor 30
may be incorporated into a downhole module dedicated as a sensor
module 10D. In one or more embodiments, the sensor 30 may be a flow
sensor configured to measure the flow rate of fluid flowing through
the flow control valve 19, 23. Other non-limiting embodiments of
the sensor 30 include valve position sensor, equipment operation
sensor, temperature sensor, pressure sensor, optical transmissivity
sensor, optical reflectivity sensor, flexural mechanical resonator
sensor, permittivity sensor, dielectric constant sensor, viscosity
sensor, conductivity sensor, acoustic velocity sensor, acoustic
impedance sensor, corrosion sensor, and radiation sensor (both
natural and neutron induced). Sensor measurements or readings are
transmitted to the controller 16 using the wireless signal. The
sensor data may then be processed by the controller 16 and sent to
an output device such as a display or printer for displaying the
data to a user or to a non-transitory computer readable medium for
storage. Additionally, the controller 16 may be configured to send
an alert signal to a user if any sensed data exceeds a threshold
value.
[0022] FIG. 4 is a flow chart for a method for performing an
operation in a borehole penetrating the earth. Block 41 calls for
disposing a downhole module in the borehole, the module being
configured to perform the operation and comprising: an anchor
device configured to anchor the module in the borehole and to be
released in order to retrieve the module, a power source disposed
on the module and configured to provide power to the module, a
signal transducer disposed on the module and configured to at least
one of transmit a wireless signal and receive a wireless signal,
and a downhole electronic device disposed on the module, coupled to
the signal transducer, and configured to operate the module and
provide communications to the module including repeating a received
wireless signal for transmission downhole or uphole. Block 42 calls
for anchoring the module in the borehole using the anchor device.
The anchor device may be actuated by a carrier, such as a wireline
or drill tubular, conveying the module in the borehole. Block 43
calls for performing the operation using the module. Non-limiting
embodiments of the operation include (a) flow control of fluid
entering the borehole from a reservoir using a remotely operated
flow control valve that is controlled by a wireless control signal
sent by a controller, (b) repeating wireless signals received from
downhole or uphole, and (c) performing measurements of a parameter
using a sensor disposed on the module and transmitting sensed data
to the surface such as to the controller. Other types of operations
may also be implemented using the module. The method 40 may also
include modulating the flow through the flow control valve to
achieve a selected flow rate (as measured by a flow sensor) using
the control signal. The method 40 may also include releasing the
anchor device and relocating the module. The releasing and
relocating may be performed by the carrier.
[0023] The above disclosed apparatus and method provide several
advantages. One advantage is that the downhole modules may be
quickly deployed with commensurate lower cost due to avoiding the
need to install, connect and maintain communications cable between
modules and the surface controller. Another advantage is that a
downhole module can be quickly retrieved for repair or replacement
if a problem develops.
[0024] 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 12, the controller 16
(or surface processing system 16), or the surface signal receiver
17 may include digital and/or analog systems. The system may have
components such as a processor, storage media, memory, input,
output, communications link, 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.
[0025] Further, various other components may be included and called
upon for providing for aspects of the teachings herein. For
example, a, cooling component, heating component, magnet,
electromagnet, sensor, electrode, transmitter, receiver,
transceiver, antenna, controller, optical unit, electrical unit,
electromechanical unit, or hydraulic unit may be included in
support of the various aspects discussed herein or in support of
other functions beyond this disclosure.
[0026] 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 any combination of terms. The term "configured"
relates one or more structural limitations of a device that are
required for the device to perform the function or operation for
which the device is configured. The term "coupled" relates to a
first component being coupled either directly to a second component
or indirectly through an intermediate component.
[0027] The flow diagrams depicted herein are just examples. There
may be many variations to this diagram or the steps (or operations)
described therein without departing from the spirit of the
invention. For instance, the steps may be performed in a differing
order, or steps may be added, deleted or modified. All of these
variations are considered a part of the claimed invention.
[0028] While one or more embodiments have been shown and described,
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 illustrations and not limitation.
[0029] 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.
[0030] 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.
* * * * *