U.S. patent application number 14/994082 was filed with the patent office on 2016-05-05 for adaptive pump control for positive displacement pump failure modes.
The applicant listed for this patent is Schlumberger Technology Corporation. Invention is credited to Kent David Harms, Albert Hoefel, Julian J. Pop, Steven Villareal.
Application Number | 20160123318 14/994082 |
Document ID | / |
Family ID | 47555881 |
Filed Date | 2016-05-05 |
United States Patent
Application |
20160123318 |
Kind Code |
A1 |
Villareal; Steven ; et
al. |
May 5, 2016 |
Adaptive Pump Control For Positive Displacement Pump Failure
Modes
Abstract
Detecting a failure mode of a fluid flow controller configured
to control fluid flow between first and second chambers of a
downhole positive displacement pump and a flow line, wherein the
positive displacement pump comprises a piston moving in an axial
reciprocating motion, and subsequently adjusting operation of the
downhole positive displacement pump based on the detected failure
mode such that the downhole positive displacement pump piston
operates differently in different axial directions.
Inventors: |
Villareal; Steven;
(Cheltenham, GB) ; Pop; Julian J.; (Houston,
TX) ; Hoefel; Albert; (Sugar Land, TX) ;
Harms; Kent David; (Richmond, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schlumberger Technology Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
47555881 |
Appl. No.: |
14/994082 |
Filed: |
January 12, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14269743 |
May 5, 2014 |
9243628 |
|
|
14994082 |
|
|
|
|
13184684 |
Jul 18, 2011 |
8757986 |
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14269743 |
|
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Current U.S.
Class: |
166/53 |
Current CPC
Class: |
E21B 47/06 20130101;
F04B 47/00 20130101; F04B 19/22 20130101; F04B 49/022 20130101;
F04B 53/14 20130101; F04B 53/16 20130101; E21B 49/10 20130101; F04B
2201/0201 20130101; F04B 47/02 20130101; E21B 44/005 20130101; F04B
49/22 20130101; F04B 49/00 20130101; F04B 53/10 20130101; F04B
2201/0603 20130101; E21B 43/121 20130101 |
International
Class: |
F04B 49/02 20060101
F04B049/02; F04B 49/22 20060101 F04B049/22; E21B 43/12 20060101
E21B043/12; F04B 53/10 20060101 F04B053/10; F04B 53/16 20060101
F04B053/16; F04B 47/00 20060101 F04B047/00; F04B 53/14 20060101
F04B053/14 |
Claims
1. An apparatus, comprising: a downhole tool conveyable within a
wellbore that extends into a subterranean formation, wherein the
downhole tool comprises: a pump comprising: a first chamber having
a first inlet valve and a first outlet valve; a second chamber
having a second inlet valve and a second outlet valve; and a piston
having opposing first and second surfaces defining respective
moveable boundaries of the first and second chambers; at least one
sensor operable to sense a first pressure in at least one of the
first and second chambers; and a controller operable to control the
first and second inlet and outlet valves in coordination with
movement of the piston to draw fluid from the subterranean
formation and expel fluid into the wellbore, wherein such control
of the first and second inlet and outlet valves is based at least
in part on the sensed first pressure and a second pressure of fluid
in at least one of the wellbore and the subterranean formation.
2. The apparatus of claim 1 wherein: the downhole tool further
comprises a flow line; the at least one sensor is operable to sense
a pressure response to pumping fluid between the flow line and one
of the first and second chambers; and the controller is further
operable to detect a failure mode of the pump based on the sensed
pressure response.
3. The apparatus of claim 1 wherein: the downhole tool further
comprises a sample chamber; and the controller is further operable
to control the first and second inlet and outlet valves in
coordination with movement of the piston to pump fluid drawn from
the subterranean formation into the sample chamber.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims priority to
U.S. patent application Ser. No. 14/269,743, entitled "Adaptive
Pump Control for Positive Displacement Pump Failure Modes," filed
May 5, 2014, which is a continuation of U.S. patent application
Ser. No. 13/184,684, entitled "Adaptive Pump Control for Positive
Displacement Pump Failure Modes," filed Jul. 18, 2011, now U.S.
Pat. No. 8,757,986, the entire disclosures of which are hereby
incorporated herein by reference.
BACKGROUND OF THE DISCLOSURE
[0002] Wells are generally drilled into the ground or ocean bed to
recover natural deposits of oil and gas, as well as other desirable
materials that are trapped in geological formations in the Earth's
crust. Wells are typically drilled using a drill bit attached to
the lower end of a drill string. Drilling fluid, or mud, is
typically pumped down through the drill string to the drill bit.
The drilling fluid lubricates and cools the drill bit, and may
additionally carry drill cuttings from the borehole back to the
surface.
[0003] Reservoir production and testing may involve drilling wells
and monitoring various subsurface formation parameters. When
drilling and monitoring, downhole tools having electric,
mechanical, and/or hydraulic powered devices may be used. In some
implementations, pump systems may be used to draw and pump
formation fluid from subsurface formations. A downhole string
(e.g., a drill string, coiled tubing, slickline, wireline, etc.)
may include one or more pump systems depending on the operations to
be performed using the downhole string, or the string may have
fluids pumped therein from a surface of the formation.
[0004] One such pump system is a positive displacement pump. A
positive displacement pump causes a fluid to move by trapping a
fixed amount of it then forcing (displacing) that trapped volume
through a discharge. Such a pump system usually produces the same
flow at a given speed (RPM) regardless of the discharge
pressure.
[0005] Commonly, multiple moving parts involved in any formation
testing tool, such as pump systems in either wireline or
measurement-while-drilling (MWD) tools, can result in equipment
failure or less than optimal performance. Further, at significant
depths, substantial hydrostatic pressure and high temperatures are
experienced, thereby further complicating matters. Still further,
formation testing tools are operated under a wide variety of
conditions and parameters that are related to both the formation
and the drilling conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present disclosure is best understood from the following
detailed description when read with the accompanying figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale. In fact, the
dimensions of the various features may be arbitrarily increased or
reduced for clarity of discussion.
[0007] FIG. 1 is a schematic view of an apparatus according to one
or more aspects of the present disclosure.
[0008] FIG. 2 is a schematic view of an apparatus according to one
or more aspects of the present disclosure.
[0009] FIG. 3 is a schematic view of an apparatus according to one
or more aspects of the present disclosure.
[0010] FIG. 4 is a flow-chart diagram of at least a portion of a
method according to one or more aspects of the present
disclosure.
[0011] FIG. 5 shows an example of pumping operation according to
one or more aspects of the present disclosure.
DETAILED DESCRIPTION
[0012] It is to be understood that the following disclosure
provides many different embodiments, or examples, for implementing
different features of various embodiments. Specific examples of
components and arrangements are described below to simplify the
present disclosure. These are, of course, merely examples and are
not intended to be limiting. In addition, the present disclosure
may repeat reference numerals and/or letters in the various
examples. This repetition is for the purpose of simplicity and
clarity and does not in itself dictate a relationship between the
various embodiments and/or configurations discussed. Moreover, the
formation of a first feature over or on a second feature in the
description that follows may include embodiments in which the first
and second features are formed in direct contact, and may also
include embodiments in which additional features may be formed
interposing the first and second features, such that the first and
second features may not be in direct contact.
[0013] One or more aspects of the present disclosure relate to
methods and apparatus for identification and mitigation of common
failure modes in formation sampling tools. For example, one or more
aspects of the present disclosure relate to detecting and
compensating for failure modes in downhole pump systems, such as in
a positive displacement pump, used to produce fluid from or inject
fluid into a fluid flow line that may be operatively connected to a
subterranean formation, an inflatable packer, or a hydraulic
actuator, among other uses.
[0014] When a multi-chamber positive displacement pump is used to
produce fluid from or inject fluid into subterranean formations, a
fluid flow controller is used to control fluid flow between the
pump chambers and the formation. Often times, such a multi-chamber
positive displacement pump changes its behavior during operation,
resulting in one or more failure modes of the positive displacement
pump. For example, failure modes may include failure of a fluid
flow controller due to clogging of the fluid flow controller in an
open position, sand accumulation in one or more chambers of the
positive displacement pump, or any combination thereof.
[0015] One or more aspects of the present disclosure provide a
pumping strategy for automatically and/or externally detecting one
or more failure modes of a downhole positive displacement pump.
Detection of the failure modes may be performed using a combination
of sensor measurements and pattern recognition techniques. Such
detection may result in a more accurate report of the volume of
fluid effectively drawn or otherwise pumped by the positive
displacement pump, leading to more accurate calculations for
contamination analysis and prediction of the time to reach a target
contamination level. Further, one or more aspects of the present
disclosure provide for compensation of the detected failure
mode(s). Compensation may be applied by changing one or more
parameters of pump operation, such as, for example, the operating
rate of the positive displacement pump.
[0016] FIG. 1 depicts a wellsite system including a downhole
tool(s) which may be configured according to one or more aspects of
the present disclosure. The wellsite drilling system of FIG. 1 can
be employed onshore and/or offshore. In the example wellsite system
of FIG. 1, a borehole 114 is formed in one or more subsurface
formations by rotary and/or directional drilling.
[0017] As illustrated in FIG. 1, a drillstring 112 is suspended
from a drill rig 110 in the borehole 114 and includes a bottom hole
assembly (BHA) 118 having a drill bit 116 at its lower end. A
surface system includes a platform and derrick assembly 100
positioned over the borehole 114. The derrick assembly 100 includes
a rotary table 120, a kelly 122, a hook 124 and a rotary swivel
126. The drillstring 112 is rotated by the rotary table 120,
energized by means not shown, which engages the kelly 122 at an
upper end of the drillstring 112. The example drillstring 112 is
suspended from the hook 124, which is attached to a traveling block
(not shown), and through the kelly 122 and the rotary swivel 126,
which permits rotation of the drillstring 112 relative to the hook
124. Additionally, or alternatively, a top drive system could be
used.
[0018] In the example depicted in FIG. 1, the surface system
further includes drilling fluid 128, which is commonly referred to
in the industry as "mud," and which is stored in a pit 130 formed
at the well site. A pump 132 delivers the drilling fluid 128 to the
interior of the drillstring 112 via a port in the rotary swivel
126, causing the drilling fluid 128 to flow downwardly through the
drillstring 112 as indicated by the directional arrow 134. The
drilling fluid 128 exits the drillstring 112 via ports in the drill
bit 116, and then circulates upwardly through the annulus region
136 between the outside of the drillstring 112 and the wall of the
borehole 114, as indicated by the directional arrows 138. The
drilling fluid 128 lubricates the drill bit 116, carries formation
cuttings up to the surface as it is returned to the pit 130 for
recirculation, and creates a mudcake layer (not shown) on the walls
of the borehole 114.
[0019] The example bottom hole assembly 118 of FIG. 1 includes,
among other things, any number and/or type(s) of
logging-while-drilling (LWD) modules or tools (one of which is
designated by reference numeral 140) and/or
measuring-while-drilling (MWD) modules (one of which is designated
by reference numeral 142), a rotary-steerable system or mud motor
144 and the example drill bit 116. The MWD module 142 measures the
azimuth and inclination of the bottom hole assembly 118 that may be
used to monitor the borehole trajectory.
[0020] The example LWD tool 140 and/or the example MWD module 142
of FIG. 1 may be housed in a special type of drill collar, as it is
known in the art, and contains any number of logging tools and/or
fluid sampling devices. The example LWD tool 140 includes
capabilities for measuring, processing and/or storing information,
as well as for communicating with the MWD module 142 and/or
directly with the surface equipment, such as, for example, a
logging and control computer 160.
[0021] The logging and control computer 160 may include a user
interface that enables parameters to be input and/or outputs to be
displayed that may be associated with the drilling operation and/or
the formation traversed by the borehole 114. While the logging and
control computer 160 is depicted uphole and adjacent the wellsite
system, a portion or all of the logging and control computer 160
may be positioned in the bottom hole assembly 118 and/or in a
remote location.
[0022] Referring to FIG. 2, illustrated is a schematic view of a
bottom hole assembly ("BHA") 200 attached at the end of a drill
string 202 in a borehole 205 according to one or more aspects of
the present disclosure. The BHA 200 comprises a "while drilling"
formation sampling tool 214 having an extendable probe 216. The
extendable probe 216 of the formation sampling tool 214 may be
fluidly coupled to a positive displacement pump (not shown). The
formation sampling tool 214 shown in FIG. 2 is configured to obtain
fluid samples.
[0023] The drill string 202 comprises a central bore therethrough
to circulate drilling fluid or mud from the surface towards a drill
bit 201. Pressure pulses may be generated in the drilling fluid
column inside the drill string 202 to convey signals (encoding data
and/or commands) between a surface system (not shown) and various
tools or components in the BHA 200. Alternatively, or additionally,
the drill string 202 may comprise wired drill pipe.
[0024] In addition to the formation sampling tool 214, the BHA 200
may comprise a drill bit 201, a near wellbore imaging tool 210, a
directional drilling sub 206, a lithology analysis tool 212, and/or
a measurement ("MWD") tool 204. The MWD tool 204 may comprise a mud
turbine generator (not shown) powered by the flow of the drilling
fluid and/or battery systems (not shown) for generating electrical
power to components in the BHA 200. The MWD tool 204 may also
comprise capabilities for communicating with surface equipment. The
MWD tool 204 also comprises one or more devices or sensors or
measuring or detecting weight-on-bit, torque, vibration, shock,
stick-slip, direction (e.g., a magnetometer), inclination (e.g., an
accelerometer), and/or gamma rays.
[0025] The near wellbore imaging tool 210 may comprise one or more
current-measuring electrodes. The current may be generated in the
BHA 200 by a coil 218 of the near wellbore imaging tool 210. The
current may then exit the BHA 200 (e.g., at the drill bit 201) and
may return to the BHA 200 through the one or more electrodes of the
near wellbore imaging tool 210. The current at the electrodes may
be measured as the BHA 200 is disposed within the formation for
drilling, as the BHA 200 is rotated within the formation, and/or as
the BHA 200 is tripped out of the formation. Thus, resistivity
images of the formation may be generated from data collected by the
near wellbore imaging tool 210, such as with relation to the
wellbore depth and/or the BHA 200 orientation within the
wellbore.
[0026] FIG. 3 is a schematic view of an apparatus illustrating an
example of a positive displacement pump configured according to one
or more aspects of the present disclosure. The example of FIG. 3
may be representative of one or more of the LWD tool 140 (FIG. 1),
and/or the formation sampling tool 214 (FIG. 2). The apparatus of
FIG. 3 may be used during the drilling, tripping, or wireline
operation. The apparatus of FIG. 3 may be conveyed in a borehole
with any method of conveyance, such as, for example, coil-tubing,
wired/unwired drill pipe, wireline cable, or any combination
thereof.
[0027] FIG. 3 shows a tester tool 31 that includes a pump module
32. A positive displacement pump 41 may include two pistons 42, 43
connected by a shaft 44 and disposed within corresponding pump
chambers 45, 46 respectively. The pump chambers 45, 46 may be
cylindrical chambers configured to accumulate a volume of fluid
extracted from/injected into a subterranean formation or device.
The dual piston 42, 43/pump chamber 45, 46 arrangement works
through positive volume displacement. The dual piston 42, 43
motion, an axial reciprocation motion, is actuated via a planetary
roller-screw 47, which is connected to a variable speed, electric
pump motor 35 via a gearbox or transmission 48. The gearbox or
transmission 48 is driven by the pump motor 35, and may be used to
vary a transmission ratio between an output shaft of the pump motor
35 and a threaded shaft 49 of the planetary roller screw 47. The
pump motor 35 may be part or integral to the positive displacement
pump 41, but alternatively may be a separate component. Power to
the pump motor 35 is supplied from a dedicated turbine (not shown)
which drives an alternator (not shown). Gaps between the components
of the pump module 32 are filled with oil 50 that may be pressure
compensated with an annulus bellows compensator shown at 50a.
[0028] The pumping action of the positive displacement pump 41 is
achieved via the planetary roller screw 47, which includes a nut
39, and the threaded shaft 49. The pump motor 35 and associated
gearbox 48 drive the threaded shaft 49 in a bi-directional mode
under the direction of a microprocessor controller, such as
controller 78. During operation of the positive displacement pump
41, the fluid gets routed to either one of the two pump chambers 45
or 46. The positive displacement pump 41 operates such that there
is one pump chamber 45 or 46 drawing fluid in from a fluid flow
line 75a, while the other pump chamber 46 or 45, respectively, is
expulsing fluid into a fluid flow line 75b. For example, a network
53 of mud check valves 66, 67, 71, and 72, acts as a fluid flow
controller configured to control the flow of fluid between the pump
chambers 45, 46 and the fluid flow lines 75a and 75b. During intake
into the pump chamber 45, fluid passes from the fluid flow line
75a, into the network of mud check valves 53 and through the check
valve 66, before entering the pump chamber 45. Upon output from the
pump chamber 45, fluid passes into the network of mud check valves
53 and through the check valve 67, before entering the fluid flow
line 75b. Similarly, upon intake into the chamber 46, fluid passes
into the network of mud check valves 53 and through the check valve
71, before entering the pump chamber 46. Upon output from the pump
chamber 46, fluid passes into the network of mud check valves 53
and through the check valve 72, before entering the fluid flow line
75b.
[0029] Then, the fluid pumped into flow line 75b may proceed, for
example, to the fluid routing and equalization valve 61 where it is
either expelled into a borehole (or borehole annulus) 18 or passed
through an hydraulic/electrical connector 59, a check valve 68 and
into one of the sample chambers 62-64 of a fluid sample collector
module 33. The pumped fluid may also be expelled into the borehole
18 via check valve 74. However, those skilled in the art will
appreciate that positive displacement pumps similar to the positive
displacement pump 41 may be configured to inject fluid into the
formation, produce fluid from the formation, inject fluid into
another downhole tool/device, such as an inflatable packer, or any
combination thereof. While only three sample chambers 62, 63, 64
are shown, it will also be noted that more or less than three
chambers 62, 63, 64 may be employed. Those skilled in the art will
appreciate that the number of chambers is not critical and the
present disclosure is not limited to three chambers. Although FIG.
3 shows a network 53 of mud check valves, those skilled in the art
will appreciate that the fluid flow controller may be any suitable
configuration and number of components capable of directing the
flow of fluid from the pump chambers 45, 46 to or from a fluid flow
line 75. For example, a fluid flow controller may be made up of one
or more solenoid valves.
[0030] In the present disclosure, the pressure sensors 57, 77 may
be used to detect a failure mode of the positive displacement pump
41. The microprocessor controller 78 is operatively connected to
the pressure sensors 57, 77. The microprocessor controller 78
includes functionality to obtain and analyze tool parameters and
measurements, such as pressure measurements from the pressure
sensors 57, 77. Alternatively or additionally, the microprocessor
controller 78 may include functionality to obtain and analyze
torque applied by the pump motor 35, load balance, current/voltage
of the alternator, output flow rate, or any combination thereof.
For example, with respect to FIG. 3, the microprocessor controller
78 is used to observe the pressure response measured by pressure
sensors 57, 77 and automatically apply compensation when a failure
mode of the positive displacement pump 41 is detected.
[0031] A failure mode of the positive displacement pump 41 may be
any mode of operation of the positive displacement pump 41 that
results in a change in the amount of volume of fluid
produced/injected by the positive displacement pump corresponding
to one stroke of the dual piston 42, 43. A failure mode may involve
one or more of the fluid flow controller components being clogged
in an open position. For example, one or more of the mud check
valves 66, 67, 71, 72 may be in a failure mode when it is lodged
open by a particle or due to erosion. In either case, one or more
of the mud check valves 66, 67, 71, 72 (or any other component of a
fluid flow controller) may not function properly, resulting, for
example, in a reduced volume of fluid received from the flow line
75a into one or more of the pump chambers 45 and 46 when the volume
of the corresponding one or more of the pump chambers 45 and 46 is
increased (or sometimes fluid not flowing the flow line 75a into
one or more of the pump chambers 45 and 46). The stroke of the pump
piston 42, 43 corresponding to increasing the volume of the chamber
while receiving the reduced volume of fluid into the chamber during
a failure mode is hereinafter referred to as an inactive stroke. In
contrast, the stroke corresponding to a pump chamber 45, 46 that
continues to accumulate fluid is hereinafter referred to as the
active stroke of the positive displacement pump 41. One or more of
the mud check valves 66, 67, 71, 72 not functioning properly may
additionally or alternatively result in a reduced volume of fluid
expelled (or no fluid flow) from one or more of the pump chambers
45 and 46 into the flow line 75b, and/or a reduced volume of fluid
pumped (or no fluid flow) from the flow line 75a into the flow line
75b.
[0032] Other examples of failure modes of the positive displacement
pump 41 involve excessive sand accumulation in one or more of the
pump chambers 45, 46. For example, during pumping, particles may be
pumped through the formation sampling tool along with formation
fluid and/or wellbore fluid. Sampling unconsolidated sand formation
is common and may lead to a failure mode in which excessive sand is
accumulated within one or both pump chambers 45, 46. As pumping
progresses, sand accumulates to the point that one chamber volume
is significantly reduced. As sand accumulates, the positive
displacement pump 41 may require excessive power to complete a full
stroke, resulting in sand particles becoming compacted.
[0033] FIG. 4 is a flow chart illustrating at least a portion of a
method for detecting and applying compensation for a positive
displacement pump failure mode according to one or more aspects of
the present disclosure. One or more of the steps shown in FIG. 4
may be omitted, repeated, and/or performed in a different order
than that shown in FIG. 4. Accordingly, the specific arrangement of
steps shown in FIG. 4 should not be construed as limiting the scope
of the present disclosure. The process of FIG. 4 may be implemented
in conjunction with one or more downhole tools of, for example, a
drill string and/or wireline tool(s) within the scope of the
present disclosure.
[0034] To begin the example process of FIG. 4, the pumping sequence
is started (ST 400). For example, under normal operation of the
positive displacement pump, the pump piston, driven by a motor,
begins its axial reciprocating motion, resulting in a first stroke
and a second stroke in the reverse direction of the first stroke.
The positive displacement pump may operate at a predetermined rate
of pumping, in which both the first and second strokes are at a
constant speed. For example, the operating rate of the positive
displacement pump may be 5 cc/s. Each stroke of the positive
displacement pump results in a volume of fluid accumulating in a
corresponding pump chamber. For incompressible fluids, the volume
produced by each stroke may be scaled to the piston displacement
multiplied by the production area of the piston. The time for
completing each stroke may be equal in both directions. That is, in
Step 400, each stroke may be symmetric, and fluid is produced (or
injected, depending on the function of the positive displacement
pump) during each stroke direction at the predetermined operating
rate of the positive displacement pump. Those skilled in the art
will appreciate that the predetermined rate of the positive
displacement pump during normal operation may be any suitable
value, and depends on the properties of the fluid being pumped, the
formation into or from which fluid is injected/extracted, and the
operating capabilities of the positive displacement pump. Further,
those skilled in the art will appreciate that the predetermined
operating rate of the positive displacement pump may be at a
maximum value during Step 400 based on the aforementioned
considerations.
[0035] Next, tool parameters and measurements are monitored (ST
402). Tool parameters and measurements may include, but are not
limited to, torque applied by the motor driving the positive
displacement pump, pressure sensors, flow meter measurements, load
balance, fluid mobility, etc. The aforementioned parameters and
measurements may be monitored by a microprocessor located downhole
and operatively connected to each of the sensors configured to
measure parameters such as those described above.
[0036] At this stage in the process, a failure mode is detected
from data received by one or more of the tools/sensors being
monitored (ST 404). More specifically, the failure mode may be
detected by, for example, observing a pattern in the pressure
response, measured by a pressure sensor located at the pump inlet,
between the first chamber and the second chamber. For example, the
pattern observed may be a difference in pressure response between
the first and second chambers. A pressure drop may be detected
during a first stroke of the positive displacement pump
corresponding to a first chamber, and an absence of a pressure drop
may be detected during a second stroke of the positive displacement
pump corresponding to a second chamber of the positive displacement
pump (in a dual chamber positive displacement pump, for example).
When the pressure response from one chamber is different from the
other chamber, this may indicate that one of the chambers is not
accumulating a same volume of fluid as another chamber, triggering
a detection of a failure mode of the positive displacement pump.
Similarly, a failure mode of the positive displacement pump may be
detected by a load imbalance observed by observing the applied
torque of a motor driving the positive displacement pump, a
difference in piston displacement (for example, during a failure
mode involving sand accumulation in one or more pump chambers), a
difference in the observed input or output flow rate, a difference
in the voltage/current measurements at the motor, or any suitable
combination thereof.
[0037] Those skilled in the art will appreciate that detecting a
failure mode (ST 404) may involve signal pattern recognition
techniques that are well-known in the art. Such pattern recognition
may be used, for example to formulate a pattern in the signal
responses from the telemetric sensors of the downhole pump system
and detect a break in the pattern, indicating a possible failure
mode. Such pattern recognition techniques may be employed when
measurement noise is large and/or non-stationary, and/or when the
range of remedial actions become more complex. One such detection
method may involve a correlation argument constructed by the
following equations:
.chi. t o ( t ) = { 1 t - t o .di-elect cons. [ n .DELTA. t p , ( n
+ 1 ) .DELTA. t p ] 0 t - t o .di-elect cons. ( ( n + 1 ) .DELTA. t
p , ( n + 2 ) .DELTA. t p ) n = 0 , 2 , 4 , ( 1 ) .DELTA. p ( t ) =
{ p f - p ( t ) t .gtoreq. t o 0 t < t o A ( k ) = .intg. t o t
k .DELTA. p ( x ) x t k = t o + k .DELTA. t p , k = 0 , 1 , 2 , A 0
( k ) = .intg. t o t k .chi. t o ( x ) .DELTA. p ( x ) x A - 1 ( k
) = .intg. t o t k .chi. t o + .DELTA. t p ( x ) .DELTA. p ( x ) x
( 2 ) ##EQU00001##
[0038] The equations assume that each of the two strokes of the
multi-chamber positive displacement pump takes the same duration
.DELTA.t.sub.p and pumping starts at t.sub.0. Thus, at t.sub.0,
pumping begins from one end of the stroke position of the positive
displacement pump. The function .chi..sub.t0(t) is a function that
helps identify the strokes in one direction versus the strokes in
the opposite direction. As defined in equation 1, this function is
equal to 1 at the times corresponding to the 1.sup.st, 3.sup.rd,
5.sup.th, etc., strokes (the stroke in a first direction), and is
equal to 0 at the times corresponding to the 2.sup.nd, 4.sup.th,
6.sup.th strokes (a stroke in a second direction reverse from the
first direction). Line 1 of equation 2 is simply the computation of
the "drawdown pressure": p.sub.f is the formation pressure (the
pressure of the fluid in the formation pores), usually measured by
performing a pretest before pumping (i.e., this value is already
known when pumping begins), and p(t) is the pressure in the pump
(measured by, for example, 57 in FIG. 3). So .DELTA.p(t) is the
"drawdown pressure", usually positive. Line 2 defines A(k) as the
"total" area below the .DELTA.p(t) curve measured between to and
until k stokes are performed. Line 3 defines A.sub.0(k) as the area
below the .DELTA.p(t) curve corresponding only to the strokes in
one direction. Line 4 defines A.sub.-1 (k) as the area below the
.DELTA.p(t) curve corresponding only to the strokes in the other
direction.
[0039] Absent a failure mode, there should be no difference between
the strokes in one direction and the other direction, so A.sub.0(k)
should be similar to A.sub.-1(k) and equal to half of the total
area A(k)/2. When a failure mode is present (e.g., a failure mode
of one or more (but not all) components of a fluid flow
controller), either A.sub.0(k) is similar to A(k) and A.sub.-1(k)
is equal to zero, or A.sub.0(k) is equal to zero and A.sub.-1(k) is
similar to A(k). When there is a complete failure (e.g., all
components of a fluid flow controller are not functioning
properly), A.sub.0(k), A.sub.-1(k), and A(k) are equal to zero.
[0040] The above set of equations and correlation argument assumes
that the piston stroke length is constant; however, those skilled
in the art will appreciate that modification of the term
definitions may allow for variable stroke lengths. In addition,
repairing of the failure mode (discussed below in ST 412) may also
be detected using similar correlation relationships.
[0041] Continuing with FIG. 4, upon detection of a failure mode of
the positive displacement pump, the optimal operating rate of the
positive displacement pump for at least one of the active and the
inactive strokes is determined (ST 406). Determining an optimal
operating rate of the positive displacement pump may involve
determining the maximum operating rate of the positive displacement
pump for the active and inactive strokes by analyzing properties of
the formation, pump parameters, and properties of the fluid being
extracted/injected. All of these factors are considered when
determining how fast the positive displacement pump should operate
while avoiding motor burnout, damage to the formation, damage to
the positive displacement pump, etc.
[0042] In ST 408, compensation is automatically applied for the
detected failure mode. Compensation may be applied by a
microprocessor located downhole (or on the surface) and operatively
connected to the tool parameters and measurement sensors used to
detect the failure mode. A variety of pump parameters may be
adjusted to apply compensation for the failure mode, depending on
the type of failure mode detected. For example, when the detected
failure mode involves a clogged fluid flow controller, applying
compensation may involve increasing the operating rate of the
positive displacement pump for the inactive stroke. Those skilled
in the art will appreciate that, in some cases, increasing the
operating rate of the positive displacement pump for one stroke
maybe be equivalent to reducing the stroke time of that stroke.
Increasing the operating rate for the inactive stroke results in
minimizing the time spent during the inactive pump stroke to
achieve the maximum volumetric pump rate (i.e., the operating rate
of the pump stroke that actually produces (or injects) fluid).
[0043] Those skilled in the art will appreciate that the present
disclosure may assume that the positive displacement pump is
operating at a maximum rate for at least the active stroke. In
other words, it may be assumed that the pump rate for the active
stroke is already at a maximum rate based on optimal fluid
properties, formation characteristics, and operating
characteristics of the positive displacement pump. In this case,
applying compensation may involve changing the operating rate of
the positive displacement pump for only the inactive stroke, as the
inactive stroke is dead time that is not resulting in accumulation
of fluid in a corresponding chamber. Those skilled in the art will
further appreciate that the aforementioned method for applying
compensation is most attractive when the operating rate of the
positive displacement pump is slow (e.g., 0.1-1 cc/s), so that
there is adequate ability to increase the pump rate of the inactive
stroke. Alternatively, when the active stroke is not already at an
optimal pump rate, applying compensation may involve changing the
operating rate of the positive displacement pump for both the
active and inactive strokes, while ensuring that, during the
failure mode, the operating rate of the positive displacement pump
for the inactive stroke is faster than that of the active
stroke.
[0044] When the failure mode is a result of excessive sand
accumulation in one or more of the chambers of the positive
displacement pump, applying compensation may involve adjusting the
stroke length of the positive displacement pump, and/or adjusting
positions of the ends of strokes. Sand accumulation in a pump
chamber reduces the displacement volume in the pump chamber by
limiting the piston stroke length. Accordingly, an example of
applying compensation for this failure mode may be to shorten the
stroke length corresponding to the chamber that has excessive sand
accumulation.
[0045] After compensation is applied, an accurate effective volume
produced/injected by the positive displacement pump may be reported
to the surface equipment (ST 410). For example, when compensation
is applied, the production corresponding to the inactive stroke is
reduced (or null), and the effective production rate is modified
accordingly. Effective volume produced is an important calculation
for contamination analysis and prediction of the time to reach a
target contamination level when a flow rate metering device is not
being used.
[0046] In ST 412, a determination is made as to whether repair of
the failure mode is detected. More specifically, adjusting one or
more pump parameters may result in repairing the detected failure
mode. This repair may be detected in much the same manner that the
failure mode is detected in ST 404. For example, when the operating
rate of the positive displacement pump for the inactive stroke is
increased, the speed at which the fluid is being discharged by the
positive displacement pump may be high. In this case, the
possibility of cleaning a clogged flow controller, for example, and
repairing the failure mode is increased.
[0047] Next, the compensation applied in ST 408 may be reversed (ST
414). For example, using the same scenario described above, a
clogged flow controller that is cleaned by the high speed of fluid
moving through the positive displacement pump may result in
decreasing the operating rate of the positive displacement pump for
the active stroke. In this case, after applied compensation is
reversed, the stroke time for both the active and inactive (which
is now also active due to the repair of the failure mode) may be
equal and constant, as during normal operation. When sand
accumulation in a pump chamber is reduced, the stroke length
corresponding to the chamber which now has less accumulated sand
may be increased from the reduction in stroke length applied during
the failure mode. Finally, the effective volume after reversing the
applied compensation is reported (ST 416) to remain accurate in the
amount of fluid volume produced/injected by the positive
displacement pump. Effective volume amounts may be reported to
tools/computing devices operating on the surface that collect data
from downhole operations.
[0048] FIG. 5 is an example illustrating positive displacement pump
operation with half-stroking occurring with subsequent compensation
applied according to one or more aspects of the present disclosure.
Specifically, FIG. 5 shows a simulated timing diagram in which a
failure mode of the positive displacement pump starts during a
pumping operation and subsequent compensation is applied.
Specifically, the example timing diagram illustrates the effect of
a failure mode on flowing pressures (a), pump piston displacement
(b), output flow rate (c), and torque applied by the motor (d)
driving the positive displacement pump. In this example, the
operating rate of the positive displacement pump is commanded at 5
cc/s. The time between switching direction is denoted as dT1 and is
equal for both stroke directions.
[0049] Normal pumping operation is shown from 1350-1475 seconds on
each diagram in FIG. 5. During normal pumping operation (500), each
stroke of the positive displacement pump is symmetric and fluid is
produced (or injected) from/into the formation during each stroke
direction at the predetermined operating rate of the positive
displacement pump.
[0050] At 1475 seconds, when the failure mode occurs (502), the
tool may not initially change behavior and continues at the
commanded operating rate of the positive displacement pump.
However, due to one of the two strokes of the piston being `dead`
(i.e., no volume of fluid accumulates in the corresponding chamber
of the positive displacement pump), the normal curves of each of
the parameters change. During the first stroke (the active stroke),
for example in timing diagram (a), the pressure drops in response
to producing fluid from the formation. During the reverse stroke
(the inactive stroke), however, the pressure gauge does not show a
response because of the failure mode (e.g., one of the check valves
in the fluid flow controller is not functioning properly), and the
pressure may remain constant and no formation load is realized. The
pressure observed during the inactive stroke may match the
formation pressure. Similarly, the output flow rate is zero at 1475
seconds in timing diagram (c), during the inactive stroke before
compensation is applied. The torque applied by the motor in timing
diagram (d) also shows that the torque load is dramatically
reduced. In timing diagram (b), which is the displacement position
of the piston, because the stroke time for the inactive stroke is
still dT1, before compensation is applied, there is no change with
respect to the displacement of the piston, as the piston moves at a
constant rate during both strokes. In this scenario, the production
rate of the positive displacement pump may be reduced by up to 50%
if compensation is not applied. By observing one or more of the
aforementioned changes in pump parameters and/or measurement sensor
data, the failure mode is analyzed and detected (by a
microprocessor controller operating downhole or on the surface)
somewhere between 1475 and 150 seconds in FIG. 5.
[0051] At 1560 seconds, after the failure mode is analyzed and
detected, compensation is applied (504). In this example, the tool
automatically changes the operating rate of the positive
displacement pump for the inactive stroke only. Thus, at 1560
seconds, compensation is automatically applied by increasing the
operating rate of the positive displacement pump on the inactive
stroke. However, as described above, other pump parameters may be
modified, depending on the type of the failure mode and the
properties of the positive displacement pump and the formation.
When the operating rate of the positive displacement pump is
changed, this also effectively reduces the stroke time for the
inactive chamber cycle, which is minimized as much as possible.
This minimized stroke time on the inactive stroke is shown as the
piston recycle time dT2 in timing diagram (b), where
dT2<<dT1. In other words, the time spent during the inactive
pump stroke is minimized to achieve the maximum volumetric pump
rate. The stroke time for the active chamber cycle remains at dT1.
This may be because the positive displacement pump is already
operating at its maximum operating rate on the active stroke.
Alternatively, the stroke time for the active chamber cycle may
also be increased, formation and pump properties permitting.
[0052] Those skilled in the art will appreciate that because the
piston recycle time dT2 is relatively small, the speed of the fluid
being discharged from the positive displacement pump may be high.
Thus, this procedure of applying compensation is best performed
with a properly configured discharge port.
[0053] While FIG. 5 is directed toward a failure mode of a fluid
flow controller (e.g., mud check valves, solenoid valves, etc.),
the same procedure may be applied to other types of failure modes.
For example, the simulation shown in FIG. 5 may also be run for a
failure mode of excessive sand accumulation in one or more pump
chambers. Such a failure mode may be detected by monitoring the
pumping pressure and other system sensors such as current, torque,
piston displacement, etc.) to determine if the pump chamber volume
is changing. Once this type of failure mode is detected, the system
may automatically adjust the stroke length such that the pump drive
is back within normal power range. The volume produced per pump
stroke may be reduced. The system may report the new volumetric
displacement of the system to remain accurate.
[0054] In view of the foregoing description and the figures, those
skilled in the art should readily recognize that the present
disclosure introduces a method, comprising detecting a failure mode
of a fluid flow controller configured to control fluid flow between
first and second chambers of a downhole positive displacement pump
and a flow line of the fluid. The positive displacement pump
operates in a first stroke during which a first volume of fluid
accumulates in the first chamber, and a second stroke in a reverse
direction from the first stroke during which a second volume of
fluid accumulates in the second chamber. The method may further
comprise automatically applying compensation for the failure mode
to maximize fluid production by adjusting at least one parameter of
the positive displacement pump.
[0055] The present disclosure also introduces a method of
unclogging a fluid flow controller in a positive displacement pump
that is in a failure mode as a result of being clogged in an open
position. Unclogging the check valve may comprise adjusting an
operating rate of the positive displacement pump so that the
operating rate of a first stroke of the positive displacement pump
is different from the operating rate of a second stroke of the
positive displacement pump, resulting in passing fluid through the
flow controller at an increased speed.
[0056] The present disclosure also introduces a method of detecting
a failure mode of at least one of a plurality of check valves
configured to control fluid flow between first and second chambers
of a positive displacement pump and a fluid flow line, wherein,
during the failure mode, only one of the first and second chambers
corresponding to an active stroke of the positive displacement pump
accumulates a volume of fluid. The method may further involve
automatically switching, during the failure mode, to an increased
operating rate of the positive displacement pump for an inactive
stroke of the positive displacement pump.
[0057] The present disclosure also introduces a method of detecting
a failure mode of a downhole positive displacement pump resulting
from excessive sand accumulation in at least one chamber of the
pump, wherein the positive displacement pump operates in a first
stroke during which a first volume of fluid accumulates in a first
chamber, and a second stroke in a reverse direction from the first
stroke during which a second volume of fluid accumulates in a
second chamber. The method may further involve automatically
reducing a stroke length of the positive displacement pump to
compensate for the excess sand accumulation in the at least one
chamber.
[0058] The present disclosure also introduces an apparatus
comprising: a positive displacement pump for a downhole tool, the
positive displacement pump being configured to produce fluid. The
positive displacement pump comprises a first chamber for collecting
a first volume of fluid pumped from the formation during a first
stroke of the pump, a second chamber for collecting a second volume
of fluid during a second stroke of the pump, the second stroke
being in a reverse direction from the first stroke, and a fluid
flow controller for controlling fluid flow between the first and
second chambers and the formation. The apparatus may further
include a microprocessor operative connected to the positive
displacement pump for: automatically detecting a failure mode of
the flow controller, and applying compensation for the failure mode
to maximize fluid production by adjusting at least one parameter of
the positive displacement pump.
[0059] The present disclosure also introduces a method comprising:
detecting a failure mode of a fluid flow controller configured to
control fluid flow between first and second chambers of a downhole
positive displacement pump and a flow line, wherein the positive
displacement pump comprises a piston moving in an axial
reciprocating motion; and adjusting operation of the downhole
positive displacement pump based on the detected failure mode such
that the downhole positive displacement pump piston operates
differently in different axial directions. The failure mode of the
downhole positive displacement pump may result in a change in the
amount of volume of fluid produced and/or injected by the downhole
positive displacement pump corresponding to one stroke of the
piston. The failure mode may comprise an inactive stroke of a
chamber of the downhole positive displacement pump, in which fluid:
does not enter the chamber or enters the chamber from an
inadvertent source. Adjusting the operation of the downhole
positive displacement pump may comprise increasing an operating
rate of the positive displacement pump for the inactive stroke. The
axial reciprocating motion of the downhole positive displacement
pump may comprise: a first stroke during which a first volume of
fluid accumulates in a first pump chamber; and a second stroke in a
reverse direction from the first stroke during which a second
volume of fluid accumulates in a second pump chamber. The piston
may move at an essentially constant speed during one of the first
and second strokes. Adjusting the operation of the downhole
positive displacement pump may comprise operating the positive
displacement pump during the first stroke differently from during
the second stroke. Adjusting the operation of the downhole positive
displacement pump may comprise increasing a stroke speed of the
piston during one of the first and second strokes. Detecting the
failure mode may comprise monitoring, using a microprocessor
located downhole, a plurality of downhole sensors and downhole tool
parameters. Detecting the failure mode may comprise: measuring a
pressure response to producing fluid from a subterranean formation
during strokes of axially-opposite directions; and observing a
pressure pattern in the pressure response of the strokes of
axially-opposite directions. Detecting the failure mode may
comprise: measuring a pressure response to producing fluid from a
subterranean formation during strokes of axially-opposite
directions; and observing a difference between pressure drops
during the strokes of axially-opposite directions. Adjusting the
operation of the downhole positive displacement pump may comprise
adjusting operation automatically in response to receipt of at
least one command from a surface tool by a microprocessor that is
located downhole and is configured to control operation of the
downhole positive displacement pump. The method may further
comprise: detecting repair of the failure mode of the flow
controller; and reversing the operation adjustment in response to
the detected repair to essentially restore identical operation of
the positive displacement pump during strokes of axially-opposite
directions. The flow controller may comprise a network of check
valves, and the failure mode may comprise at least one check valve
being clogged in an open position. Operation of the downhole
positive displacement pump may produce fluid from or inject fluid
into a subterranean formation via the flow line, and adjusting
operation of the downhole positive displacement pump may be
performed while maintaining fluid communication between the flow
line and the subterranean formation. The failure mode may comprise
excessive sand accumulation in at least one chamber of the positive
displacement pump. Adjusting the operation of the downhole positive
displacement pump may comprise reducing a length of strokes in one
of the first and second chambers. The method may further comprise
conveying an apparatus, via wireline or drill string, in a borehole
extending into a subterranean formation, wherein the apparatus
comprises the fluid flow controller, the downhole positive
displacement pump, and the flow line.
[0060] The present disclosure also introduces a method comprising:
detecting a clogging of a fluid flow controller in a downhole
positive displacement pump that is in a failure mode as a result of
being clogged in an open position; and unclogging the fluid flow
controller by adjusting an operating rate of the positive
displacement pump so that the operating rate of a first stroke of
the positive displacement pump is different from the operating rate
of a second stroke of the positive displacement pump, resulting in
passing fluid through the fluid flow controller at an increased
speed, wherein: in the failure mode, the first stroke corresponds
to fluid flowing from a flow line through the fluid flow controller
into a first chamber of the downhole positive displacement pump;
and in the failure mode, the second stroke corresponds to: fluid
not flowing from the flow line through the flow controller into a
second chamber of the positive displacement pump; or fluid flowing
into the second chamber from an inadvertent source. The adjusted
operating rate of the downhole positive displacement pump for the
second stroke may be faster than for the first stroke. The method
may further comprise: detecting an unclogging of the flow
controller; and restoring the initial operating rate of the
positive displacement pump for the second stroke upon detection of
the unclogging of the fluid flow controller.
[0061] The foregoing outlines features of several embodiments so
that those skilled in the art may better understand the aspects of
the present disclosure. Those skilled in the art should appreciate
that they may readily use the present disclosure as a basis for
designing or modifying other processes and structures for carrying
out the same purposes and/or achieving the same advantages of the
embodiments introduced herein. Those skilled in the art should also
realize that such equivalent constructions do not depart from the
spirit and scope of the present disclosure, and that they may make
various changes, substitutions and alterations herein without
departing from the spirit and scope of the present disclosure.
[0062] The Abstract at the end of the present disclosure is
provided to comply with 37 C.F.R. .sctn.1.72(b) to allow the reader
to quickly ascertain the nature of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims.
* * * * *