BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure
This disclosure relates to apparatus and methods for wirelessly communicating data between a well and the surface.
2. Background Information
Wells (also referred to as “wellbores” or “boreholes”) are drilled and completed to produce hydrocarbons (oil and gas) from one or more production zones penetrated by a wellbore. A typical completed well may include a metallic casing that lines the well. Cement is generally placed between the casing and the well to provide a seal between the formation surrounding the well and the casing. Perforations made in the formation through the casing at selected locations across from the producing formations (also referred to as the “production zones” or “reservoirs”) allow the formation fluid containing the hydrocarbons to flow into the cased well. The formation fluid flows to the surface via a production tubing placed inside the casing because the pressure in the production zone is generally higher than the pressure caused by the weight of the fluid column in the well. An artificial lift mechanism, such as an electrical submersible pump (“ESP”) or a gas-lift mechanism is often employed when the formation pressure is not adequate to push the fluid in the well to the surface.
A variety of devices are used in the well to control the flow of the fluid from the production zones to optimize the oil and gas production over the life of the well. Remotely-controlled flow control valves and chokes are often used to control the flow of the fluid. Chemicals are injected at certain locations in the well via one or more tubes that run from the surface to the production zones to inhibit the formation of harmful chemicals, such as corrosion, hydrate, scale, hydrogen sulfide, methane, asphaltene, etc. A number of sensors are typically placed in the well to provide information about a variety of downhole parameters, including the position of the valves and chokes, pressure, temperature, fluid flow rate, acoustic signals responsive to water front and surface or downhole induced signals in the subsurface formations, resistivity, porosity, permeability, water-cut, etc. The measurement data is typically transmitted to the surface via conductors, such as electrical wires, that run from the surface to selected locations in the well. Signals are also sent from the surface to the downhole sensors and devices via such conductors to control their operations. Such conductors (also referred to herein as data communication “links”) sometimes degrade over time. It is therefore desirable to have a data communication system that may be less prone to degradation.
The present disclosure provides improved apparatus, systems and methods for communicating data between a well and the surface.
SUMMARYIn one aspect, a well data communication system is disclosed that includes a conduit placed in a well, the conduit having a non-liquid medium therein, and a transducer that transmits wireless signals through the medium in the conduit that are representative of a selected information. The system may further include one or more repeaters associated with the conduit that receive the wireless signals transmitted by the transducer and retransmit the received signals wirelessly through the medium in the conduit. The system may further include a receiver that receives the signals transmitted by the transducer or the repeaters and a processor that processes the received signals to determine the selected information or to estimate a property of interest. The wireless signals may be radio frequency signals. The information may relate to downhole sensor measurements, downhole devices, surface sensor measurements, surface devices, stored in a suitable medium, received from a remote unit, etc. The transducer and/or any of the repeaters may be a transceiver and each may further be an autonomous device. The system may further include a transducer at the surface that transmits wireless signals, such as radio frequency signals, to a location in the well (a “downhole location”) via the medium in the conduit or another conduit that runs from the surface to the downhole location. Each of the transducers and repeaters may transmit and/or receive signals at a plurality of frequencies.
In another aspect, an apparatus is disclosed for use in a well that includes a conduit that has a non-liquid medium therein and which conduit is configured to be deployed in the well, and a transmitter that is configured to transmit wireless signals, which may be radio frequency signals, from one a downhole location and/or a surface location via the medium in the conduit.
In another aspect, a method is disclosed that includes transmitting wireless signals relating to selected information through a non-liquid filled conduit deployed in a well.
Examples of the more important features of a well data communication system and methods have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features that will be described hereinafter and which will form the subject of the claims. The summary is provided to provide the reader with broad information and is not intended to be used in any way to limit the scope of the claims.
BRIEF DESCRIPTIONFor a detailed understanding of the apparatus and methods for communicating information between a well and the surface, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements generally have been given like numerals, wherein:
FIG. 1A shows a schematic diagram of an exemplary well that is configured to provide data communication between devices in the well and a surface controller according to one embodiment of the disclosure;
FIG. 1B shows a schematic diagram of certain controllers and devices at the surface that may be utilized to establish data communication between the well and the surface according to one embodiment of the disclosure; and
FIG. 2 shows a functional block diagram of a transducer that may be utilized to transmit wireless signals in a well system, such as shown inFIGS. 1A and 1B.
DETAILED DESCRIPTION OF EMBODIMENTSFIGS. 1A and 1B (collectively referred to as “FIG.1”) collectively show schematic diagrams of one embodiment of awell system100 that includes a data communication system between a completed well50 and thesurface112 according to one embodiment of the disclosure.FIG. 1A shows the schematic diagram of the equipment of the well system that is below thesurface112, whileFIG. 1B shows the functional block diagram of exemplary equipment of thewell system100 that may be placed at thesurface112. Thesystem100 shows the well50 formed in aformation55 that producesformation fluids56aand56b(such as hydrocarbons) from twoexemplary production zones52a(upper production zone) and52b(lower production zone) respectively. Thewell50 is shown lined with acasing57 containingperforations54aadjacent theupper production zone52aandperforations54badjacent thelower production zone52b. A packer64, which may be a retrievable packer, positioned above or uphole of the lowerproduction zone perforations54a, isolates thelower production zone52bfrom theupper production zone52a. Ascreen59badjacent to theperforations54bmay be installed to prevent or inhibit solids, such as sand, from entering into the wellbore from thelower production zone54b. Similarly, ascreen59amay be used adjacent the upperproduction zone perforations59ato prevent or inhibit solids from entering into thewell50 from theupper production zone52a.
Formation fluid56bfrom thelower production zone52benters theannulus51aof thewell50 through theperforations54aand into atubing53 via aflow control valve67. Theflow control valve67 may be a remotely controlled sliding sleeve valve or any other suitable valve or choke that is configured to regulate the flow of the fluid from theannulus51ainto theproduction tubing53. Anadjustable choke40 in thetubing53 may be used to regulate the fluid flow from thelower production zone52bto thesurface112. Theformation fluid56afrom theupper production zone52aenters theannulus51b(the annulus portion above the packer64) viaperforations54a. Theformation fluid56aenters production tubing orline45 viainlets42. An adjustable valve orchoke44 regulates the fluid flow into thetubing45. Each valve, choke and other devices in the well may be operated electrically, hydraulically, mechanically and/or pneumatically by a surface controller, such as acontrol unit150 and/or by a downhole controller, such as acontrol unit60. The fluid from theupper production zone52aand thelower production zone52benter theline46.
When the formation pressure is not sufficient to push thefluid56aand/orfluid56bto the surface, an artificial lift mechanism, such as an electrical submersible pump (ESP), gas lift system or other desired systems may be utilized to lift the fluids from thewell50 to thesurface112. In the system10, anESP30 in amanifold31 is shown as the artificial lift mechanism, which receives theformation fluids56aand56band pumps such fluids viatubing47 to thesurface112. Acable134 provides power to theESP30 from a surface power source132 (FIG. 1B). Thecable134 also may include two-waydata communication links134aand134b(FIG. 1B), which may include one or more electrical conductors or fiber optic links to provide two-way signal and data communication between theESP30, ESP sensors SEand anESP control unit130.
Still referring toFIGS. 1A and 1B, in one aspect, a variety of sensors are placed at suitable locations in the well50 to provide measurements or information relating to a number of downhole parameters of interest. In one aspect, one or more gauge or sensor carriers, such as acarrier15, may be placed in the production tubing to house any number of suitable sensors. Thecarrier15 may include one or more temperature sensors, pressure sensors, flow measurement sensors, resistivity sensors, sensors that may provide information about density, viscosity, water content or water cut, etc., and chemical sensors that provide information about scale, corrosion, hydrate, paraffin, hydrogen sulfide, emulsion, asphaltene, etc. Density sensors may provide fluid density measurements for fluid produced from each production zone and that of the combined fluid from two or more production zones. A resistivity sensor or another suitable sensor may provide measurements relating to the water content or the water-cut of the fluid mixture received from each production zones and/or for the combined fluid. Other sensors may be used to estimate the oil/water ratio and gas/oil ratio for each production zone and for the combined fluid. The temperature, pressure and flow sensors provide measurements for the pressure, temperature and flow rate of the fluid. Additional gauge carriers may be used to obtain the above-noted and other measurements relating to theupper production zone52a. Also, downhole sensors may be used at other desired locations to provide measurements relating to the presence and extent of chemicals downhole. Additionally, sensors S1-Smmay be permanently installed in thewellbore50 to provide measurements, such as acoustic, seismic or microseismic measurements, formation pressure and temperature measurements, resistivity measurements and measurements relating to the properties of the casing51 andformation55. Such sensors may be installed in thecasing57 or between thecasing57 and theformation55. Microseismic and other sensors may be used to detect water fronts, which may imbalance the composition of the fluids being produced, thereby providing early warning relating to the formation of certain chemicals. Pressure and temperature changes or expected changes may provide early warning of changes in the chemical composition of the production fluid. Additionally, thescreen59aand/orscreen59bmay be coated with tracers that are released due to the presence of water, which tracers may be detected at the surface or downhole to determine or predict the occurrence of water breakthrough. EPS sensors SEmay provide information relating to theESP30, such as power to the ESP, frequency, flow rate, temperature, pressure, differential pressure across ESP, presence of certain chemicals, such as corrosion, scale, hydrate, hydrogen sulfide, asphaltene, etc. Sensors also may be provided at the surface, such as a sensor for measuring the water content in the received fluid, total flow rate for the received fluid, fluid pressure at the wellhead, temperature, etc. Other devices may be used to estimate the production of sand for each zone.
In general, sufficient sensors may be suitably placed in the well50 and thesurface112 to obtain measurements relating to each desired parameter of interest. Such sensors may include, but are not limited to: sensors for measuring pressures corresponding to each production zone, pressure along the wellbore, pressure inside the tubings carrying the formation fluid, pressure in the annulus; sensors for measuring temperatures at selected places along the wellbore; sensors for measuring fluid flow rates corresponding to each of the production zones, total flow rate, flow through the ESP; sensors for measuring ESP temperature and pressure; chemical sensors for providing signals relating to the presence and extent of chemicals, such as scale, corrosion, hydrates, paraffin, emulsion, hydrogen sulfide and asphaltene; acoustic or seismic sensors that measure signals generated at the surface or in offset wells and signals due to the fluid travel from injection wells or due to a fracturing operation; optical sensors for measuring chemical compositions and other parameters; sensors for measuring various characteristics of the formations surrounding the well, such as resistivity, porosity, permeability, fluid density, etc. The sensors may be installed in the tubing in the well or in any device or may be permanently installed in the well. For example, sensors may be installed in the wellbore casing, in the wellbore wall or between the casing and the wall. The sensors may be of any suitable type, including electrical sensors, mechanical sensors, piezoelectric sensors, fiber optic sensors, optical sensors, etc. The signals from the downhole sensors may be partially or fully processed downhole by a downhole controller, such ascontroller60, which may include a microprocessor and associated electronic circuitry and programs and then communicated to the surface controller150 (FIG. 1A) via a signal/data link, such aslink101. The signals from downhole sensors may also be sent directly to thecontroller150.
A variety of hydraulic, electrical and data communication lines (collectively designated by numeral20 (FIG. 1A) are run inside the well50 to operate the various devices in the well50 to obtain measurements and other data from the various sensors in the well50 and to provide power and data communication between the surface and downhole equipment. As an example, a tube ortubing21 may supply or inject a particular chemical from the surface into the fluid56bvia a mandrel36. Similarly, a tubing22 may supply or inject a particular chemical to the fluid56ain the production tubing via amandrel37. Separate lines may be used to supply the additives at different locations in the well50 or to supply different types of additives.Lines23 and24 may operate thechokes40 and44 and may be used to operate any other device, such as thevalve67.Line25 may provide electrical power to certain devices downhole from a suitable surface power source. One or more non-liquid filled conduits, such asconduits101 and102 may be deployed in the well to establish two-way data communication between sensors and devices in the system. A downhole control unit, such ascontroller60 and a surface controller, such ascontroller150 may be used to process signals from these sensors and devices and then transmit desired information wirelessly via theconduits101 and/or102. The sensors and the devices may communicate with the controllers by any suitable links, including, but not limited to, electrical conductors, optical fibers, acoustic signals, electromagnetic signals, and wireless signals.
In one aspect, one or more conduits or tubing, such astubing101 and102 are placed or run between a suitable location in the well50 and the surface to establish wireless data communication between a well50 and thesurface112. These tubings may be made from any suitable material, such as an alloy or a composite material capable of withstanding the downhole environment for an extended time period. In one aspect, thetubings101,102 may be filled with a suitable gas, such as air or an inert gas, such as nitrogen or argon. In another aspect, thetubings101,102 may be partially, substantially or fully evacuated. InFIG. 1,tubing101 is shown in signal communication with adownhole transducer110, which may include an RF data transmitter an/or a transceiver. Thetransducer110 may include a receiver that receives signals or data from one or more sensors, such a sensors S1-Smin the well50 and other devices. Such data or signals may be provided to thetransducer110 by coupling the sensors to the transducer via electrical, fiber optic or wireless links. The transducer may be an active device and may include a processor, memory and other circuitry that can process the signals received from the sensors, process the received signals and transmit the processed signals as wireless signals through the medium in thetubing101 at one or more selected frequencies. A transducer120 (FIG. 1B) spaced from thetransducer110 receives the wireless signals and sends the received signals to a surface controller orcontrol unit150. Thesurface controller150 decodes the signals received from thereceiver120 and uses the signals to manage one or more operations of thewell system100. The surface controller also may send data signals to thetransducer120, which transmits the received signals via the non-liquid media in thetubing101 as wireless signals. Alternatively, aseparate transducer122 andtubing102 may be used to send the wireless signals from thesurface112 to adownhole controller60 via the non-liquid medium in thetubing102. Each of thetransducers110 and120 may be configured to transmit the wireless signals at more than one frequency. The signals may be coded signals and may use any desired signals modulation technique, such as amplitude, phase and frequency modulation.
Wells can be very long and can extend to several thousand meters. In some such wells, the radio frequency signal transmitted by a transducer,such transducer110, may attenuate and may not be detectable by thereceiver120. In other cases, it may be desirable to transmit radio frequency signals between a branch wellbores or a branch wellbore and a main wellbore or the surface via a conduit in which the signals may attenuate to an undesirable extent. Also, thetransducer110 over time may not be able to send signals that are strong enough to reach a desired receiver in thesystem100. In any such cases, one or more repeaters, such as R1-Rn, (generally designated by numeral114) may be deployed in the well50 and configured in a manner so that they can detect signals from the conduit medium and retransmit the detected signals to thereceiver120. Similar transmitters may be deployed inconduit102.
Each of the transducers, such astransducer110, and the repeaters R1-Rnmay be an autonomous device.FIG. 2 shows a functional diagram of an autonomous transducer orrepeater200 according to one embodiment of the disclosure. Thedevice200 may include: aprocessor210, such as a micro-controller, microprocessor or another suitable circuit combination; a data storage device ormemory device212, such a solid state memory device (Read-only-memory “ROM,” random access memory (“RAM”, flash memory, etc.) that is suitable for downhole application; and one or more computer programs or sets ofinstructions214 that may be stored in thememory212 and which programs are accessible to theprocessor210. Theprocessor210 communicates with thememory212 and theprograms214 vialinks211 and213 respectively. Apower source220 provides power to the processor as shown bylink231 and to the other components of thedevice200 vialink223. In operation, signals T1-Tpfrom sensors and other devices may be received by aninterface230 that is configured to receive such signals. Theinterface230 may be configured to condition such signals, such as by amplifying and digitizing the signals. Theprocessor210 processes receives the signals from the interface and processes such signals, such as by sequencing the signals, putting the signals in appropriate data packets, assigning addresses of the sensors or the devices from which such signals are received, etc. and sends such processed signals vialink241 to atransmitter240 that transmits the signals wirelessly via the medium in the conduit. The wireless signals, such as radio frequency signals, sent from the surface via theconduits101 and/or102 are received by a second interface or areceiver245, which conditions the received signals and provides them to theprocessor210. Theprocessor210 then may process these signals and may control one or moredownhole devices260 in response to such signals. The processor may store any information in thememory device212 and use anyprograms214 to perform one or more of the functions described herein. Theprocessor210 is shown to communicate with thereceiver radio frequency245 vialink243, withdownhole devices260 vialink261. Alternatively, the signals sent from the surface may be received by adownhole controller60 or received by thetransducer110 and passed on to thecontroller60. Thus, in one aspect, thedownhole transducer110 receives signals from one or more devices or sensors in the well or from a controller in the well and transmits signals representative of the received signals as wireless signals, such as RF signals, through a non-liquid filled conduit placed in the well. A receiver spaced from the downhole transducer detects the RF signals and transmits to a surface controller for further use. The surface controller may send RF signals to a downhole receiver via the same or a separate non-liquid filled conduit. One or more repeaters placed between the transducer and the surface receiver may be used to receive and retransmit the signals sent by the transducer.
Referring back toFIG. 1B, in one aspect, the exemplary equipment shown inFIG. 1B may be utilized to manage and control the various operations of thewell system100 in response to the signals received from thedownhole transducer110. In one aspect, thecontroller150 may manage injection of additives from achemical injection unit120 into the well50 to enhance production from one or more zones in response to the signals received from a chemical sensor that may provide information about the presence of certain chemicals, such as scale, hydrate, corrosion, asphaltene, hydrogen sulfide, etc. or in response to a water-cut sensor, resistivity sensor, etc.
In another aspect, thecentral controller150 may control the operation of one or more downhole devices directly or via adownhole control unit160 and lines21-25 by sending commands via alink161. The commands may be instructions to alter the position of a choke or a sliding sleeve, etc and such commands may be in response to signals received from one or more downhole sensors, surface sensors, based on programmed instructions provided to the controller and/or signals received from a remote controller, such ascontroller185 that may communicate with thecontroller150 via anysuitable link189, such as Ethernet, the Internet, etc. In another aspect, thecentral controller150 may control the operation of theESP30 directly or via anESP controller130. The ESP controller may control power to the ESP from apower source132 in response to the signals received from the ESP sensors and/or signals received from thecentral controller150.
Still referring toFIGS. 1 and 2, a system is disclosed that includes: a non-liquid filled-conduit (“conduit”) in a well; at least one sensor that provides signals relating to a parameter of interest; and a transducer in the wellbore that transmits wireless signals, such as radio-frequency signals, through the non-liquid medium in the conduit that are representative of the signals provided by the at least one sensor. The system may further include a repeater in the well that receives the signals transmitted by the transducer in the well and retransmits the received signals as radio frequency signals through the medium in the conduit. The system may further include a surface receiver that receives the signals transmitted by the transducer and a processor that process the signals received by the surface receiver to estimate the property of interest. The sensor in the well may be a: (i) pressure sensor; (ii) temperature sensor; (iii) an acoustic sensor; (iv) a flow rate measuring sensor; (v) a water-cut measurement sensor; (vi) a resistivity measurement sensor; (vii) a chemical detection sensor; (viii) a fiber optic sensor; and (ix) a piezoelectric sensor. The conduit may be: (i) substantially filled with air; (ii) substantially filled with a gas; or (iii) at least partially evacuated. The conduit may extend from a selected location in the wellbore to an uphole location. The uphole location may be: (i) a location at the surface of the earth; (ii) a location in the wellbore uphole of the data transmission device: (iii) a location at a sea bed; (iv) a location on a land rig; and (v) a location on an offshore platform. The sensors may communicate with the transducer in the well via: (i) an electrical wire; (ii) an optical fiber; and (iii) wirelessly.
Each transducer and/or repeater include: a circuit that receives the signals from the at least one sensor; and a signal conditioner that conditions the received signals; and a transmitter that transmits signals as radio frequency signals through the medium in the conduit. The system may further include a power source that provides electrical power to the transducer. The power source may be: (i) a battery; (ii) a power generation unit that generates electrical power in the wellbore; or (iii) a power unit at the surface that supplies electrical power via an electrical conductor disposed in or along the conduit. The conduit may be placed along a production tubing that carries fluid from the wellbore to the surface; along a casing in the well or between a casing in the well and the formation surrounding the well. Additionally, the transducer may: (i) receive analog signals from the at least one sensor and transmit analog signals that are representative of the received signals over a radio frequency; (ii) receive analog signals from the at least one sensor and transmit digital signals that are representative of the received signals over a radio frequency and/or receive digital signals from the at least one sensor and transmit digital signals that are representative of the received signals over a radio frequency.
In another aspect, the system may include: a plurality of sensors distributed in the wellbore, each sensor in the plurality of sensors providing the at least one? signals relating to a measurement made by such sensor; a conduit in the wellbore that is gas-filled or at least partially evacuated; a plurality of transceivers in the wellbore; and wherein each sensor in the plurality of sensors provides signals to a corresponding transceiver in the plurality of transducers, wherein each transceiver transmits the signals received from its associated sensor wirelessly through the conduit. Each transducer may comprise a unique address. Each transducer may be a transceiver. Energy to the transceivers may be provided by: (i) a battery; (ii) a thermoelectric generator; and (iii) a combination of a battery and a thermoelectric generator. Any transceiver also may include a sensor for taking a measurement relating to a parameter of interest, which may relate to health of the transceiver, formation or the well.
Also, a method for communicating information between a location in a wellbore and an uphole location is disclosed, which method comprises: placing a non-liquid filled conduit in the wellbore; placing at least one sensor in the wellbore that provides signals relating to a parameter of interest; placing a first device in the conduit downhole; receiving signals provided by the at least one sensor at the first device; transmitting signals representative of the received signals wirelessly by the first device through the conduit; and receiving the signals transmitted by the first device at a second device uphole of the first device; processing the received signals to estimate the property of interest; and recording the property of interest in a suitable medium. The method may further comprise one or more repeaters that receive the signals transmitted by the first device and transmits the received signals to the second device. The parameter of interest may be: (i) pressure; (ii) temperature; (iii) resistivity; (iv) fluid flow rate; (v) capacitance; (v) viscosity; (vi) density; (vii) presence of a chemical in the wellbore; (viii) paraffin; (ix) scale; (x) hydrate; (xi) hydrogen sulfide; (xii) asphaltene; (xiii) corrosion; (xiv) water content; and (xv) presence of gas.
While the foregoing disclosure is directed to certain disclosed embodiments and methods, various modifications will be apparent to those skilled in the art. It is intended that all modifications that fall within the scopes of the claims relating to this disclosure be deemed as part of the foregoing disclosure. Also, an abstract is provided in this application with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.