Apparatus and method for an autonomous robotic system for performing activities in a well

• US 20050288819A1
• Filed: 10/11/2002
• Published: 12/29/2005
• Est. Priority Date: 10/11/2002
• Status: Active Grant

• Current Assignee: Intelligent Robotic Corporation
• Original Assignee: Intelligent Robotic Corporation
• Inventors: de Guzman, Neil
• Granted Patent: US 7,303,010 B2
• Time in Patent Office: Days
• US Class Current: 700/245
• CPC Class Codes: F16L 55/32 being self-contained
• CPC Class Codes: F16L 55/38 driven by fluid pressure
• CPC Class Codes: F16L 55/40 of the body
• CPC Class Codes: F16L 55/48 Indicating the position of the pig or mole in the pipe or conduit

Abstract

An autonomous robot performs maintenance and repair activities in oil and gas wells, and in pipelines. The robot uses the well and pipeline fluids to provide most of the energy required for the its mobility, and to charge a turbine from which it may recharge batteries or power a motor for additional propulsion. A control system of associated systems controls the robot, enabling the robot to share plans and goals, situations, and solution processes with wells, pipelines, and external control systems. The control system includes decision aids in a series of knowledge bases that contain the expertise in appropriate fields to provide intelligent behavior to the control system. The intelligent behavior of the control system enables real time maintenance management of wells and pipelines, through actively collecting information, goal-driven system, reasoning at multiple levels, context sensitive communication, activity performing, and estimation of the operators'"'"' intent.

Claims

1. A robotic tool that can move autonomously through oil and gas wells using a combination of well liquids conveyance and an “

inch-worm”

drive.

2. The “

inch-worm”

moves by extending forward from a clamped reference to a new clamped reference ahead of the first and after the extension the clamped reference is closed. The extension arm then contracts toward the second clamped reference, and this is repeated to create movement. A mechanism to extend and contract the tool is placed between the clamps.

a. The clamps are hydraulically actuated to allow

i. A control arm force

ii. Control slippage

iii. Dithering the force element on the casing (or tubing) to control free fall of the tool into the well to save battery power.

b. The clamps also serve as centralizing mechanisms to permit better control of tool direction and to permit better control of transport through the well.

3. Conservation of power using gravity and well production flow to move the tool through the well bore without a direct drive.

4. In consideration of the above, use of either an iris or an inflatable member.

5. An iris that is used for “

free fall”

of the tool into the well and also for “

free lift”

by controlling the circumference of the iris.

a. In free fall the iris acts as a parachute. The iris extends to leave a small gap between the circumference of the iris and the I.D. of the tubing or casing. A motion sensor feeds a control system that extends and retracts the iris to maintain speed. The control system also recognizes the deviation of the hole so that the “

inch-worm”

gains control in highly deviated or horizontal wells.

b. In free lift the iris further expands (in a producing well) to use the production flow to lift the tool.

c. An inflatable element can also be used in place of the iris, and its diameter can be controlled using hydraulic actuation.

6. Clamps that are radially placed around the diameter of the tool and allow decentralization of the tool for movement into off center tubing sections.

7. Features include a motor to drive a hydraulic pump.

a. Pump to provide system pressure

b. Fluid reservoir to provide fluid to system which is pressure balanced to wellbore-pressure

c. Sensors to measure:

i. Acoustic sensors to locate objects ahead of the motion of the tool

ii. Hydraulic pressure to multiple points

iii. Motor current to measure hydraulic pressure levels

iv. Sensor to measure orientation of the tool referenced to the high side of the well

v. Strain gauges to measure clamping load

d. A control system that uses the sensor data to maintain the force on the tubing to prevent slippage, to control advancing of the tool against obstacles in the path, to detect leaks in the hydraulics, and to other such requirements as needed to allow the tool to move through be well and perform tasks downhole.

8. The tool can accommodate many different tubing and casing sizes because of the propulsion method.

9. A turbine driven electrical generator disposed in the tool to recharge batteries while the tool is not moving, or if the tool is moving downhole under iris, dithered free-fall, or other downward motion.

10. Articulation along with reference clamp to allow movement into side holes or laterals.

11. Quality control through the use of pattern recognition to be able to define proper and improper functioning activities taking placed in the well such as:

a. Location of equipment,

b. Flow from perforations

c. Corrosion

d. Erosion of components

12. Quality control through surveying and mapping the well bore to assess functioning of equipment, components, and materials.

13. The embodiment of the tool includes a force generation device to move sleeves, valves, and other devices. Such a device can be powered by the hydraulic circuits or by separate electromechanical drives.

14. The tool can carry a suite of sensors to measure well bore and formation characteristics. Sensors can include gamma ray, collar locator, temperature, pressure, fluid-flow in the well, acoustic noise, borehole televiewer, and other devices well known in the industry.

15. If the tool is used for perforation, the perforating gun can remain clamped in location, and the tool can report its measurement and request permission to fire.

16. The tool may also have either one-way or bi-directional communication with the surface.

17. A command and control loop that enables the robot to perceive, plan, and act using symbolic processing concepts.

18. A bidirectional data flow providing decision aids to the operator and interpreting the operators'"'"' intent.

19. A means of controlling numerous automated wells and devices through collaboration between numerous intelligent agents that share plans and goals and shared situation assessments as indicated by interpretation of data from sensors.

20. A series of knowledge bases contain expertise needed by the software that controls the behavior of the intelligent devices.

21. The knowledge include a concept knowledge base, plan goal graphs, monitors and notifications, intermediate representations, and knowledge calculations.

22. A layered system that defines the interactions between the system and its environment.

23. A plan goal graph that represents the knowledge of the system required to manage wells, fiber optic smart wells, and electronic fields.

24. Dynamic planning though a life cycle of planned activities enables changing of plans in response to changing circumstances.