Methods and systems for downhole sensing and communications in gas lift wells

• US 10,273,801 B2
• Filed: 05/23/2017
• Issued: 04/30/2019
• Est. Priority Date: 05/23/2017
• Status: Active Grant

• Current Assignee: Baker Hughes Oilfield Operations LLC (Baker Hughes Company)
• Original Assignee: General Electric Company
• Inventors: Shah, Vimal Vinod, Brazil, Stewart Blake, Chin, Wilson Chun-Ling, Lusted, Roderick Mark
• Primary Examiner(s): Andrews, D.
• Assistant Examiner(s): Akaragwe, Yanick A
• Application Number:
  US15/603,093
• Publication Number:
  US 20180340413A1
• Time in Patent Office: 707 Days
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 43/123 Gas lift valves
• CPC Class Codes: E21B 47/18 through the well fluid , e.g. mud pressure pulse telemetry
• CPC Class Codes: F01D 15/10 Adaptations for driving, or combinations with, electric generators
• CPC Class Codes: F01D 21/00 Shutting-down of machines or engines, e.g. in emergency; Regulating, controlling, or safety means not otherwise provided for

Abstract

A sensing and communication system for a gas lift well is provided. The gas lift well includes a casing, production tubing positioned within the casing, and a gas lift valve coupled to the production tubing. The sensing and communication system includes a turbine configured to rotate in response to an injected gas stream flowing through the turbine, wherein the turbine is positioned one of i) within an annulus defined between the production tubing and the casing and ii) within the gas lift valve, an alternator coupled to the turbine and configured to generate electrical power from rotation of the turbine, and at least one sensor coupled to the alternator and configured to operate using the generated electrical power.

Claims

1. A sensing and communication system for a gas lift well, the gas lift well including a casing, production tubing positioned within the casing, and a gas lift valve coupled to the production tubing, said sensing and communication system comprising:

a turbine configured to rotate in response to an injected gas stream flowing through said turbine, wherein said turbine is positioned in a turbine chamber within the gas lift valve, such that the turbine chamber is in flow communication with a first conduit defined in the gas lift valve;

a resonator chamber; and

a flapper for controlling flow communication between the first conduit and said resonator chamber, wherein said resonator chamber generates a tone when said resonator chamber is in flow communication with the first conduit and the injected gas stream flows through the first conduit.

2. The sensing and communication system in accordance with claim 1, wherein said sensing and communication system further comprises:

an alternator coupled to said turbine for generating electrical power from rotation of said turbine; and

at least one sensor coupled to said alternator and configured to operate using the generated electrical power.

3. The sensing and communication system in accordance with claim 2, further comprising:

a flapper controller communicatively coupled to said flapper, said flapper controller configured to selectively open and close said flapper to generate an acoustic signal that travels through the injected gas stream.

4. The sensing and communication system in accordance with claim 3, wherein said flapper controller is further configured to operate using the generated electrical power.

5. The sensing and communication system in accordance with claim 3, further comprising a surface decoder configured to detect and process the generated acoustic signal.

6. The sensing and communication system in accordance with claim 1, further comprising a surface decoder configured to detect and process the generated tone.

7. A gas lift well comprising:

a casing;

production tubing positioned within said casing;

a gas lift valve coupled to said production tubing; and

a sensing and communication system comprising;

a turbine configured to rotate in response to an injected gas stream flowing through said turbine, wherein said turbine is positioned in a turbine chamber within said gas lift valve, wherein the turbine chamber is in flow communication with a first conduit defined in said gas lift valve;

a resonator chamber; and

a flapper for controlling flow communication between the first conduit and said resonator chamber, wherein said resonator chamber generates a tone when said resonator chamber is in flow communication with the first conduit and the injected gas stream flows through the first conduit.

8. The gas lift well in accordance with claim 7, wherein said sensing and communication system further comprises:

an alternator coupled to said turbine and for generating electrical power from rotation of said turbine; and

at least one sensor coupled to said alternator and configured to operate using the generated electrical power.

9. The gas lift well in accordance with claim 8, further comprising:

a flapper controller communicatively coupled to said flapper, said flapper controller configured to selectively open and close said flapper to generate an acoustic signal that travels through the injected gas stream.

10. The gas lift well in accordance with claim 9, wherein said flapper controller is further configured to operate using the generated electrical power.

11. The gas lift well in accordance with claim 9, further comprising a surface decoder configured to detect and process the generated acoustic signal.

12. The gas lift well in accordance with claim 7, further comprising a surface decoder configured to detect and process the generated tone.

13. A method of assembling a sensing and communication system for a gas lift well that includes a casing, production tubing positioned within the casing, and a gas lift valve coupled to the production tubing, said method comprising:

positioning a turbine in a turbine chamber within the gas lift valve, the turbine configured to rotate in response to an injected gas stream flowing through the turbine, wherein the turbine chamber is in flow communication with a first conduit defined in the gas lift valve;

coupling a resonator chamber in flow communication with the first conduit; and

coupling a flapper between the first conduit and the resonator chamber, the flapper for controlling flow communication between the first conduit and the resonator chamber, where the resonator chamber generates a tone when the resonator chamber is in flow communication with the first conduit and the injected gas stream flows through the first conduit.

14. The method of claim 13, further comprising installing a surface decoder configured to detect an acoustic signal traveling through the injected gas stream.

15. The method of claim 14, wherein installing a surface decoder comprises installing a surface decoder configured to detect an acoustic signal generated by a resonator chamber.