Zonal isolation devices including sensing and wireless telemetry and methods of utilizing the same

• US 10,590,759 B2
• Filed: 08/01/2017
• Issued: 03/17/2020
• 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: Ertas, Mehmet Deniz, Pastusek, Paul E., Disko, Mark M.
• Primary Examiner(s): Aziz, Adnan
• Application Number:
  US15/665,936
• Publication Number:
  US 20180058198A1
• Time in Patent Office: 959 Days
• CPC Class Codes: E21B 33/12 Packers; Plugs used for cementing E21B33/134, E21B33/16
• CPC Class Codes: E21B 34/06 in wells
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/07 Temperature
• CPC Class Codes: E21B 47/10 Locating fluid leaks, intrusions or movements
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: E21B 47/138 Devices entrained in the flow of well-bore fluid for transmitting data, control or actuation signals
• CPC Class Codes: E21B 47/14 using acoustic waves
• CPC Class Codes: E21B 47/18 through the well fluid , e.g. mud pressure pulse telemetry
• CPC Class Codes: E21B 49/08 Obtaining fluid samples or testing fluids, in boreholes or wells
• CPC Class Codes: E21B 49/0875 determining specific fluid parameters

Abstract

Zonal isolation devices including sensing and wireless telemetry and methods of utilizing the same are disclosed herein. The zonal isolation devices include an isolation body, a sensor, and a wireless telemetry device. The zonal isolation devices may be incorporated into a hydrocarbon well that also includes a wellbore and a wireless data transmission network. The methods include methods of conveying a wireless signal within a well. The methods include detecting a property of the well, transmitting a wireless output signal, conveying the wireless output signal, and receiving the wireless output signal.

Claims

1. A zonal isolation device configured to be placed within a fluid conduit of a well with a wireless data transmission network, the zonal isolation device comprising:

an isolation body configured to transition from a contracted conformation, in which a characteristic dimension of the isolation body is less than a characteristic dimension of the fluid conduit of the well such that the zonal isolation device is free to move within the fluid conduit, and an expanded conformation, in which the characteristic dimension of the isolation body is increased such that the isolation body is positionally fixed within the fluid conduit and restricts fluid flow of a wellbore fluid within the fluid conduit;

a sensor configured to detect at least one property of the well, wherein at least a portion of the sensor is in direct physical contact with a downhole tubular that defines at least a portion of the fluid conduit when the zonal isolation device is positioned within the fluid conduit and in the expanded conformation; and

a wireless telemetry device configured to transmit a wireless output signal to the wireless data transmission network, wherein the wireless output signal is an acoustic signal, wherein the wireless telemetry device is operatively attached to the isolation body when the isolation body is in both the contracted conformation and the expanded conformation, and further, wherein the wireless output signal is indicative of the at least one property of the well.

2. The zonal isolation device of claim 1, wherein the sensor is operatively attached to the isolation body when the isolation body is in both the contracted conformation and the expanded conformation.

3. The zonal isolation device of claim 1, wherein the at least one property of the well includes at least one of:

(i) a property indicative of a seal integrity of the zonal isolation device within the fluid conduit;

(ii) a property indicative of an integrity of the downhole tubular that at least partially defines the fluid conduit;

(iii) a temperature;

(iv) a pressure;

(v) a vibrational amplitude;

(vi) a vibrational frequency;

(vii) a strain within the zonal isolation device;

(viii) an electrical conductivity of the wellbore fluid;

(ix) a flow rate of the wellbore fluid;

(x) a presence of a multiphase flow within the fluid conduit;

(xi) a chemical composition of the wellbore fluid;

(xii) a density of the wellbore fluid; and

(xiii) a viscosity of the wellbore fluid.

4. The zonal isolation device of claim 1, wherein the sensor includes at least one of:

(i) a pressure sensor;

(ii) a differential pressure sensor configured to detect a pressure differential between an uphole side of the zonal isolation device and a downhole side of the zonal isolation device;

(iii) an acoustic sensor;

(iv) a vibration sensor;

(v) an acoustic transmitter;

(vi) an acoustic receiver;

(vii) a temperature sensor;

(viii) a strain gauge;

(ix) an electrical conductivity sensor;

(x) a fluid flow meter;

(xi) a multiphase flow sensor;

(xii) a chemical composition sensor;

(xiii) a fluid density sensor; and

(xiv) a viscosity sensor.

5. The zonal isolation device of claim 1, wherein the wireless telemetry device is configured to transmit an entirety of the wireless output signal via a non-metallic conveyance medium and across a gap that extends between the wireless telemetry device and the downhole tubular.

6. The zonal isolation device of claim 1, wherein the wireless telemetry device is programmed to transmit the wireless output signal responsive to satisfaction of a predetermined data transmission condition, and further wherein the predetermined data transmission condition includes at least one of:

(i) detection, by the sensor, of less than a lower threshold pressure drop across the zonal isolation device;

(ii) detection, by the sensor, of greater than an upper threshold pressure drop across the zonal isolation device;

(iii) detection, by the sensor, of greater than a threshold fluid flow rate past the zonal isolation device; and

(iv) detection, by the sensor, of failure of a seal between the isolation body and the downhole tubular that at least partially defines the fluid conduit.

7. The zonal isolation device of claim 1, wherein the wireless telemetry device includes a wireless transmitter configured to generate the wireless output signal.

8. The zonal isolation device of claim 7, wherein the wireless transmitter includes at least one of:

(i) an electromagnetic transmitter; and

(ii) a radio frequency transmitter.

9. The zonal isolation device of claim 7, wherein the wireless transmitter includes an acoustic transmitter.

10. The zonal isolation device of claim 9, wherein the acoustic transmitter includes a piezoelectric transmitter element configured to vibrate at a data transmission frequency to generate the wireless output signal.

11. The zonal isolation device of claim 10, wherein the acoustic transmitter further includes a rigid plate operatively linked to the piezoelectric transmitter element and configured to vibrate with the piezoelectric transmitter element.

12. The zonal isolation device of claim 11, wherein the rigid plate is in direct physical contact with the piezoelectric transmitter element.

13. The zonal isolation device of claim 11, wherein the rigid plate extends between the piezoelectric transmitter element and the wellbore fluid when the zonal isolation device is positioned within the fluid conduit.

14. The zonal isolation device of claim 11, wherein, when the zonal isolation device is positioned within the fluid conduit and in the expanded conformation, the rigid plate at least one of:

(i) is in contact with a tubular body that defines the fluid conduit;

(ii) is in direct physical contact with the tubular body; and

(iii) is separated from the tubular body by a gap.

15. The zonal isolation device of claim 1, wherein the wireless telemetry device further includes a wireless receiver configured to receive a wireless input signal.

16. The zonal isolation device of claim 1, wherein the zonal isolation device includes at least one of a swellable packer, an annular swellable packer, and a bridge plug.

17. The zonal isolation device of claim 1, wherein the wireless telemetry device is configured to receive a wireless input signal in the form of a wireless actuation signal, and further wherein the zonal isolation device includes a wirelessly triggered actuator configured to be transitioned between an unactuated configuration and an actuated configuration responsive to receipt of the wireless actuation signal.

18. The zonal isolation device of claim 17, wherein the wirelessly triggered actuator includes a wirelessly actuated valve that defines an open configuration, in which the wirelessly actuated valve permits fluid flow of the wellbore fluid therethrough, and a closed configuration, in which the wirelessly actuated valve resists fluid flow of the wellbore fluid therethrough, wherein the unactuated configuration defines the closed configuration, wherein the actuated configuration defines the open configuration, and further wherein, when in the open configuration, the wirelessly actuated valve is configured to facilitate fluid flow within the fluid conduit and past the zonal isolation device.

19. A method of conveying a wireless signal within a well, wherein the well includes a wellbore that extends within a subterranean formation, the method comprising:

detecting, with a sensor of a zonal isolation device, a property of the well;

transmitting an acoustic wireless output signal, which is indicative of the property of the well, with a wireless telemetry device of the zonal isolation device, wherein the zonal isolation device is positioned within a fluid conduit that extends within the wellbore, and wherein at least a portion of the sensor is in direct physical contact with a downhole tubular, which defines at least a portion of the fluid conduit, when the zonal isolation device is in an expanded conformation;

conveying the acoustic wireless output signal along a length of the wellbore; and

receiving the acoustic wireless output signal with a relay node receiver of a relay node, wherein;

(i) the relay node is positioned within the fluid conduit; and

(ii) the relay node is spaced-apart from the zonal isolation device along the length of the wellbore.

20. The method of claim 19, wherein the conveying includes conveying an entirety of the acoustic wireless output signal via a non-metallic conveyance medium over at least a portion of a transmission distance between the zonal isolation device and the relay node.

21. The method of claim 19, wherein the zonal isolation device and a tubular body, which defines the fluid conduit, define a gap therebetween, wherein a wellbore fluid fills the gap, and further wherein the conveying includes conveying the acoustic wireless output signal across the gap.

22. The method of claim 19, wherein the zonal isolation device includes a non-metallic isolation body configured to transition from a contracted conformation, in which a characteristic dimension of the non-metallic isolation body is less than a characteristic dimension of the fluid conduit such that the zonal isolation device is free to move within the fluid conduit, and an expanded conformation, in which the characteristic dimension of the non-metallic isolation body is greater than the characteristic dimension of the fluid conduit such that the isolation body is positionally fixed within the fluid conduit and restricts fluid flow of a wellbore fluid within the fluid conduit, and further wherein the zonal isolation device is in the expanded conformation.

23. The method of claim 22, wherein the fluid conduit is at least partially defined by a metallic downhole tubular that extends within the wellbore, wherein the zonal isolation device is in direct physical contact with the metallic downhole tubular, and further wherein the conveying includes conveying the entirety of the acoustic wireless output signal from the wireless telemetry device of the zonal isolation device, through the non-metallic isolation body of the zonal isolation device, into the metallic downhole tubular, and along the metallic downhole tubular to the relay node.

24. The method of claim 22, wherein the fluid conduit is at least partially defined by the wellbore, wherein the zonal isolation device is in direct physical contact with the wellbore, and further wherein the conveying includes conveying an entirety of the acoustic wireless output signal from the wireless telemetry device of the zonal isolation device via at least one of the wellbore fluid that extends within the wellbore, a subterranean formation that defines the wellbore, and a cement that extends within the wellbore.

25. The method of claim 19, wherein the detecting includes detecting at least one of:

(i) a property indicative of a seal integrity of the zonal isolation device within the fluid conduit;

(ii) a pressure drop across the zonal isolation device;

(iii) a property indicative of an integrity of the downhole tubular that at least partially defines the fluid conduit;

(iv) a temperature;

(v) a pressure;

(vi) a vibrational amplitude;

(vii) a vibrational frequency;

(viii) a strain within the zonal isolation device;

(ix) an electrical conductivity of a wellbore fluid;

(x) a flow rate of the wellbore fluid;

(xi) a presence of a multiphase flow within the fluid conduit;

(xii) a chemical composition of the wellbore fluid;

(xiii) a density of the wellbore fluid; and

(xiv) a viscosity of the wellbore fluid.