Downhole multiphase flow sensing methods

• US 10,526,888 B2
• Filed: 08/01/2017
• Issued: 01/07/2020
• Est. Priority Date: 08/30/2016
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Song, Limin, Zhang, Yibing, Disko, Mark M., Clawson, Scott William, Walker, Katie M.
• Primary Examiner(s): Wills, III, Michael R
• Application Number:
  US15/666,328
• Publication Number:
  US 20180058209A1
• Time in Patent Office: 889 Days
• CPC Class Codes: E21B 43/14 Obtaining from a multiple-zone well
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/107 using acoustic means
• CPC Class Codes: E21B 47/114 using light radiation
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves
• CPC Class Codes: G01F 1/56 by using electric or magnetic effects G01F1/66 takes precedence
• CPC Class Codes: G01F 1/66 by measuring frequency, phase shift or propagation time of electromagnetic or other waves, e.g. using ultrasonic flowmeters
• CPC Class Codes: G01F 1/74 Devices for measuring flow of a fluid or flow of a fluent solid material in suspension in another fluid
• CPC Class Codes: G01P 5/16 using Pitot tubes , e.g. Machmeter

Abstract

Provided are systems and methods for in-situ zonal assessment of multiphase fluid flow in one or more production zones of a production well, including for at least one production zone sensing one or more fluid flow parameters via at least one sensor disposed in a production zone; at least one sensor communications node being in electrical communication with an associated sensor, the at least one sensor communications node positioned along a tubular body in the production zone proximate an associated at least one sensor, and receiving signals from the associated at least one sensor; sending the acoustic signals from the at least one sensor communications node to a receiver at a surface via a series of intermediate communications nodes, node-to-node, the signals being indicative of one or more fluid flow parameters, the series of intermediate communications nodes being spaced along the tubular and configured to transmit acoustic waves; assessing one or more fluid flow parameters for the one or more production zones in response to signals received from a topside communications node.

Claims

1. An in-situ system for assessing production conditions of one or more production zones of a fluid producing well comprising at least one production zone, the system comprising:

at least one sensor disposed along a tubular body in the production zone of the fluid producing well, each sensor configured to measure a parameter indicative of fluid flow within production tubing in that zone;

at least one sensor communications node placed along and affixed to a wall of the tubular body in that production zone, the at least one sensor communications node being in communication with at least one associated sensor and configured to receive signals therefrom;

a topside communications node;

one or more intermediate communications nodes spaced along and attached to the wall of the tubular body, wherein the intermediate communications nodes are configured to transmit signals received from the sensor communications node(s) to the topside communications node, in substantially a node-to-node communications arrangement;

a receiver at a well surface configured to receive signals from the topside communications node; and

a topside data acquisition system structured and arranged to communicate with the topside communications node;

wherein each of the at least one sensors includes a material probe to measure parameters related to material properties with the fluid surrounding the sensor, wherein the material probe is a piezoelectric transducer configured to be excited to propagate acoustic energy along the tubular body;

wherein a composition of the fluid in the tubular body can be determined based on a level of the propagated acoustic energy lost to the fluid in the tubular body.

2. The system of claim 1, wherein the fluid producing well is a multi-zone fluid producing well.

3. The system of claim 1, wherein at least one sensor resides within the sealed housing of its associated sensor communications node.

4. The system of claim 1, wherein the well surface is an earth surface or a production platform offshore.

5. The system of claim 1, wherein each of the one or more intermediate communications nodes and/or each of the at least one sensor communications nodes are configured to transmit acoustic waves, radio waves, low frequency electromagnetic waves, inductive electromagnetic waves, light, or combinations thereof.

6. The system of claim 1, wherein each of the one or more intermediate communications nodes and each of the at least one sensor communications nodes are configured to transmit acoustic waves, providing near real-time information to the topside data acquisition system.

7. The system of claim 6, wherein each of the one or more intermediate communications nodes and each of the at least one sensor communications nodes comprises a sealed housing, a power source residing within the sealed housing, and at least one electro-acoustic transducer.

8. The system of claim 7, wherein each of the one or more intermediate communications nodes further comprises a transceiver associated with the at least one electro-acoustic transducer configured to receive and relay the acoustic waves.

9. The system of claim 7, wherein the at least one sensor communications node further comprises a transceiver associated with the at least one electro-acoustic transducer that is configured to communicate with the at least one sensor and transmit acoustic waves in response thereto.

10. The system of claim 9, wherein the acoustic waves represent asynchronous packets of information comprising a plurality of separate tones, with at least some of the acoustic waves being indicative of a sensed parameter.

11. The system of claim 10, wherein a frequency band for the acoustic wave transmission by the transceivers operates from 80 kHz to 105 kHz.

12. The system of claim 7, wherein each of the at least one sensors resides within the housing of its associated sensor communications node, and the electro-acoustic transducer within the associated sensor communications node converts signals from the sensor into acoustic signals for an associated transceiver.

13. The system of claim 6, wherein the acoustic waves provide data that is modulated by (i) a multiple frequency shift keying method, (ii) a frequency shift keying method, (iii) a multi-frequency signaling method, (iv) a phase shift keying method, (v) a pulse position modulation method, or (vi) an on-off keying method.

14. The system of claim 1, wherein the at least one sensor employs passive acoustic monitoring, active acoustic measurements, electrical-acoustic impedance measurements, electromagnetic signature detection, sonar monitoring, radar monitoring, or radiation monitoring.

15. The system of claim 1, wherein data transmitted topside is utilized by the topside data acquisition system for assessing production conditions of a production zone of a multi-zone fluid producing well.

16. The system of claim 1, wherein the intermediate communications nodes are spaced apart such that each intermediate communications node resides on its own joint of production tubing.

17. The system of claim 1, wherein the intermediate communications nodes are spaced at about 10 to 1,000 foot (3.0 to 304.8 meter) intervals;

and the transceivers transmit data in acoustic form at a rate exceeding about 50 bps.

18. The system of claim 1, further comprising, for at least one production zone of the fluid producing well, one or more production optimization control devices.

19. The system of claim 18, wherein the one or more production optimization control devices are selected from an inflow control device, an autonomous inflow control device, an outflow control device, an actuated downhole shut-off valve, and an isolation device.

21. The method of claim 14, wherein the intermediate communications nodes are configured to transmit acoustic waves, radio waves, low frequency electromagnetic waves, inductive electromagnetic waves, light, or combinations thereof.

22. The method of claim 14, wherein the step of transmitting the signals received from the one or more sensors via a transceiver employs the at least one sensor communications node configured to transmit acoustic waves, radio waves, low frequency electromagnetic waves, inductive electromagnetic waves, light, or combinations thereof.

23. The method of claim 14, wherein the intermediate communications nodes and the at least one sensor communications node are configured to transmit acoustic waves, providing real-time information as to production conditions of a production zone.

24. The method of claim 14, wherein each of the intermediate communications nodes comprises a sealed housing;

a power source residing within the housing; and

at least one electro-acoustic transducer.

25. The method of claim 24, wherein each of the intermediate communications nodes further comprises a transceiver associated with the at least one electro-acoustic transducer structured and arranged to receive and relay the acoustic waves.

26. The method of claim 14, wherein the at least one sensor communications node comprises:

a sealed housing;

a power source residing within the housing; and

at least one electro-acoustic transducer.

27. The method of claim 26, wherein the at least one sensor communications node further comprises a transceiver associated with the at least one electro-acoustic transducer that is structured and arranged to communicate with the at least one sensor and transmit acoustic waves in response thereto.

28. The method of claim 27, wherein the acoustic waves represent asynchronous packets of information comprising a plurality of separate tones, with at least some of the acoustic waves being indicative of a sensed property.

29. The method of claim 14, wherein each of the at least one sensor communications node is configured to receive signals from the associated sensor, and transmit acoustic signals indicative of readings taken by the at least one sensor.

30. The method of claim 14, wherein the production condition further comprises a flow rate of the fluid in the tubular body, and wherein each of the at least one sensors includes a flow probe to measure parameters associated with the flow rate of the fluid adjacent the sensor, wherein the flow probe is a piezoelectric noise meter, and wherein the method further comprises:

using the piezoelectric noise meter, measuring an intensity of flow noise in the tubular body; and

based on a correlation between flow noise and flow rate, determining the flow rate of

the fluid in the tubular body.

20. An in-situ method for assessing production conditions of one or more production zones of a multi-zone fluid producing well, comprising:

sensing one or more fluid flow parameters via at least one sensor positioned along a tubular body in at least one production zone of the multi-zone fluid producing well;

receiving signals from the at least one sensor with at least one sensor communications node attached to a wall of the tubular body;

transmitting the received signals via a transceiver to an intermediate communications node attached to the wall of the tubular body;

relaying signals received by the intermediate communications node to an additional intermediate communications node via a transceiver;

relaying signals received by the additional intermediate communications node to a topside communications node via a transceiver;

assessing a production condition of each production zone in response to signals received from the topside communications node; and

optimizing production performance of one or more production zones of the multi-zone fluid producing well;

wherein the production condition is a composition of the fluid in the tubular body, and wherein each of the at least one sensors includes a material probe to measure parameters related to material properties with the fluid surrounding the sensor, wherein the material probe is a piezoelectric transducer, and wherein the method further comprises;

exciting the piezoelectric transducer to propagate acoustic energy along the tubular body;

determining acoustic energy lost to the fluid in the tubular body; and

based on a level of acoustic energy loss, determining the composition of the fluid in the tubular body.

31. An in-situ method for assessing production conditions of one or more production zones of a multi-zone fluid producing well, comprising:

sensing one or more fluid flow parameters via at least one sensor positioned along a tubular body in at least one production zone of the multi-zone fluid producing well;

receiving signals from the at least one sensor with at least one sensor communications node attached to a wall of the tubular body;

transmitting the received signals via a transceiver to an intermediate communications node attached to the wall of the tubular body;

relaying signals received by the intermediate communications node to an additional intermediate communications node via a transceiver;

relaying signals received by the additional intermediate communications node to a topside communications node via a transceiver;

assessing a production condition of each production zone in response to signals received from the topside communications node; and

optimizing production performance of one or more production zones of the multi-zone fluid producing well;

wherein the production condition is a flow distribution at different depths in the tubular body, each of the at least one sensors comprising a pitot array sensor, the pitot array sensor including

a plurality of pitot tubes, each of the pitot tubes being inserted into the tubular body at

a different depth from others of the plurality of pitot tubes, and

a corresponding plurality of piezoelectric transducers, wherein each of the pitot tubes

is in communication with a respective piezoelectric transducer;

wherein the method further comprises;

using signals sensed by the pitot tubes and communicated to the respective piezoelectric transducers to determine the flow distribution in the tubular body.

32. An in-situ method for assessing production conditions of one or more production zones of a multi-zone fluid producing well, comprising:

sensing one or more fluid flow parameters via at least one sensor positioned along a tubular body in at least one production zone of the multi-zone fluid producing well;

receiving signals from the at least one sensor with at least one sensor communications node attached to a wall of the tubular body;

transmitting the received signals via a transceiver to an intermediate communications node attached to the wall of the tubular body;

relaying signals received by the intermediate communications node to an additional intermediate communications node via a transceiver;

relaying signals received by the additional intermediate communications node to a topside communications node via a transceiver;

assessing a production condition of each production zone in response to signals received from the topside communications node; and

optimizing production performance of one or more production zones of the multi-zone fluid producing well;

wherein the production condition is a flow velocity of fluid in the tubular body, and further comprising;

sending a first acoustic signal from a first intermediate communications node to a second intermediate communications node, wherein the second intermediate communications node is separated from the first intermediate communications node by a known distance;

measuring a first time required for the first signal to pass through fluid in the tubular body from the first intermediate communications node to the second intermediate communications node;

sending a second acoustic signal from the second intermediate communications node to the first intermediate communications node;

measuring a second time required for the second signal to pass through fluid in the tubular body from the second intermediate communications node to the first intermediate communications node; and

using the first time, the second time, and the known distance, determining the flow velocity of the fluid in the tubular body.

33. The method of claim 32, further comprising repeating the steps at a different time with respect to a previous time and measuring the change in acoustic response with between the different time and the previous time to determine whether a physical change in fluid flow has occurred.

34. The method of claim 32, wherein the production condition further includes a composition of the fluid in the tubular body, the method further comprising:

using the first time, the second time, and the known distance, determining a speed of sound in the fluid in the tubular body; and

based on the speed of sound in the fluid, determining the composition of the fluid in the tubular body.

35. An in-situ method for assessing production conditions of one or more production zones of a multi-zone fluid producing well, comprising:

sensing one or more fluid flow parameters via at least one sensor positioned along a tubular body in at least one production zone of the multi-zone fluid producing well;

receiving signals from the at least one sensor with at least one sensor communications node attached to a wall of the tubular body;

transmitting the received signals via a transceiver to an intermediate communications node attached to the wall of the tubular body;

relaying signals received by the intermediate communications node to an additional intermediate communications node via a transceiver;

relaying signals received by the additional intermediate communications node to a topside communications node via a transceiver;

assessing a production condition of each production zone in response to signals received from the topside communications node; and

optimizing production performance of one or more production zones of the multi-zone fluid producing well;

wherein the production condition comprises a flow rate of the fluid in the tubular body, and wherein each of the at least one sensors includes a flow probe to measure parameters associated with the flow rate of the fluid adjacent the sensor, wherein the flow probe is a piezoelectric noise meter, and wherein the method further comprises;

using the piezoelectric noise meter, measuring an intensity of flow noise in the tubular body; and

based on a correlation between flow noise and flow rate, determining the flow rate of the fluid in the tubular body.