Method and apparatus for communicating coded messages in a wellbore

• US 5,579,283 A
• Filed: 06/03/1993
• Issued: 11/26/1996
• Est. Priority Date: 07/09/1990
• Status: Expired due to Term

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Bouldin, Brett W., Holcombe, Michael W., Lehr, Douglas J., Owens, Steve C., Rothers, David E.
• Primary Examiner(s): Moskowitz, Nelson
• Application Number:
  US08/071,422
• Time in Patent Office: 1,272 Days
• Field of Search: 367/83-85, 367/134, 367/166, 367/197, 175/40, 175/48, 73/151, 181/102, 181/103, 166/250, 166/374, 166/66.4
• US Class Current: 367/83
• CPC Class Codes: E21B 23/00 Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells setting of casings, screens or liners E21B43/10
• CPC Class Codes: E21B 23/065 setting tool actuated by explosion or gas generating means
• CPC Class Codes: E21B 33/1295 actuated by fluid pressure
• CPC Class Codes: E21B 34/06 in wells
• CPC Class Codes: E21B 34/063 Valve or closure with destructible element, e.g. frangible disc E21B34/103 takes precedence
• CPC Class Codes: E21B 34/066 electrically actuated
• CPC Class Codes: E21B 34/102 with means for locking the closing element in open or closed position E21B34/105 and E21B34/108 take precedence
• CPC Class Codes: E21B 43/1185 Ignition systems
• CPC Class Codes: E21B 43/11852 hydraulically actuated
• CPC Class Codes: E21B 47/007 Measuring stresses in a pipe string or casing for locating blocked portions of pipes E21B47/09
• CPC Class Codes: E21B 47/06 Measuring temperature or pressure
• CPC Class Codes: E21B 47/18 through the well fluid , e.g. mud pressure pulse telemetry
• CPC Class Codes: E21B 47/22 by negative mud pulses using a pressure relieve valve between drill pipe and annulus
• CPC Class Codes: E21B 47/24 by positive mud pulses using a flow restricting valve within the drill pipe
• CPC Class Codes: G01L 9/0002 using variations in ohmic resistance G01L9/0051 takes precedence

Abstract

A method and apparatus for communicating coded messages in a wellbore between a transmission node and a reception node is provided. The coded messages are messages are impressed upon a fluid column which extends between the transmission node and the reception node. A transmission apparatus is provided at the transmission node which is in communication with the fluid column, for altering pressure of the fluid column to generate at least a portion of the coded message. A reception apparatus is provided at the reception node. The reception apparatus includes a rigid structural component with an exterior surface which is in direct contact with fluid column and an interior surface which is not in contact with the fluid column, and a sensor assembly which detects elastic deformation of the rigid structural component. The transmission apparatus is utilized to alter pressure of the fluid column in a predetermined pattern to generate at least one coded message. The reception apparatus is utilized to detect the coded message in the fluid column through changes in elastic deformation of the rigid structural component.

Claims

1. A method of communicating a coded message in a wellbore between a transmission node and a reception node, through a fluid column extending therebetween, comprising the method steps of:

providing a transmission apparatus at said transmission node which is in communication with said fluid column;

for for generating an acoustic pressure pulse to produce at least a portion of said coded message;

providing a reception apparatus at said reception node which includes;

(a) a rigid structural component with an exterior surface which is in contact with said fluid column and an interior surface which is not in contact with said fluid column;

(b) a sensor assembly which detects elastic deformation of said rigid structural component;

utilizing said transmission apparatus to generate acoustic pressure pulses in said fluid column in a predetermined pattern to generate said coded message; and

utilizing said reception apparatus to detect said coded message in said fluid column through changes in elastic deformation of said rigid structural component.

2. A method according to claim 1, wherein said sensor assembly includes a fluid body which is in communication with said interior surface of said rigid structural component, but which is not in communication with said fluid column, and which is responsive to said changes in elastic deformation of said rigid structural component.

3. A method according to claim 2, wherein said sensor assembly further includes a pressure sensor within said fluid body for directly sensing pressure changes in said fluid body to detect elastic deformation of said rigid structural component.

4. A method according to claim 1, wherein said sensor assembly includes at least one strain sensor which is coupled to said interior surface of said rigid structural component and which is responsive to changes in elastic deformation of said rigid structural component.

5. A method according to claim 1, wherein said rigid structural component of said reception apparatus comprises a mandrel member which at least partially defines a central bore through a wellbore tubular member.

6. A method according to claim 1, further comprising:

providing a processor;

programming said processor to identify particular input electrical signal patterns with particular predefined processor tasks;

generating electrical signals with said reception apparatus which correspond to changes in elastic deformation of said rigid structural component and directing said electrical signals to said processor as an input; and

utilizing said processor to perform said particular predefined processor tasks in response to detection of particular electrical signal patterns.

7. A method according to claim 6:

wherein said particular predefined processor tasks include providing an activation signal for at least one electrically-actuable wellbore tool; and

wherein said method further includes initiating activation of a particular wellbore tool with said processor in response to receipt of a particular electrical signal pattern at said reception apparatus.

8. A method according to claim 6:

wherein said particular predefined processor tasks include providing an output signal which switches at least one wellbore tool between selected ones of a plurality of operating states; and

wherein said method further includes switching a particular one of said at least one wellbore tool between selected ones of said plurality of operating states with said processor in response to receipt of a particular electrical signal pattern at said reception apparatus.

9. A method according to claim 6:

wherein said particular electrical signal patterns define said coded message with operator-selectable coded message attributes of;

(a) number of consecutive electrical signals, each corresponding to an elastic deformation of said rigid structural component; and

(b) time between consecutive electrical signals;

which distinguish one particular coded messages from other coded messages.

10. A method according to claim 6, further including:

providing a programming unit;

providing a programming interface in electrical communication with said processor; and

utilizing said programming unit and said programming interface to program said processor to provide a particular output in response to receipt of a particular electrical signal pattern from said reception apparatus.

11. A method according to claim 10:

wherein said reception apparatus includes a plurality of power-consuming electrical components including said processor;

said method further including the method step of maintaining at least a portion of said power-consuming electrical components in an off condition until at least one signal is received at said programming interface.

12. A method according to claim 11, further comprising:

returning said at least a portion of said power-consuming electrical components to said off condition if no additional signals are received at said programming interface within a predetermined time interval.

13. A method according to claim 1, wherein said step of utilizing said reception apparatus includes:

utilizing said reception apparatus to detect said coded message in said fluid column through substantially continuously monitoring of rates of change in elastic deformation of said rigid structural component.

14. A method according to claim 1:

wherein said sensor assembly generates electrical signals corresponding to elastic deformation of said rigid structural component;

wherein said reception apparatus further includes a signal processor for identifying and isolating rates of change in elastic deformation of said rigid structural component which correspond to rates of change in fluid pressure amplitude of said fluid column above a predetermined rate threshold; and

wherein said step of utilizing said reception apparatus comprises utilizing said reception apparatus to detect said coded message in said fluid column through monitoring of rates of change in fluid pressure amplitude of said fluid column as detected by elastic deformation of said rigid structural component.

15. A method according to claim 1:

wherein said reception apparatus includes a plurality of power-consuming electrical components; and

said method further comprising the method step of maintaining at least a portion of said power-consuming electrical components in an off condition until said reception apparatus detects at least one change in elastic deformation of said rigid structural component.

16. A method according to claim 15, further comprising:

returning said at least a portion of said power-consuming electrical components to said off condition if at least one of the following conditions occur;

(a) detected changes in elastic deformation fail to define a coded message; and

(b) additional changes in elastic deformation do not occur within a predetermined time interval.

17. A method of switching a remotely located wellbore tool between modes of operation, comprising:

providing (a) an electrically-actuable wellbore tool, (b) a pressure sensor, and (c) a programmable controller, electrically connected to provide electrical signals from said pressure sensor as an input to said programmable controller;

programming said programmable controller to provide a predetermined electrical signal as an output to said electrically-actuable wellbore tool in response to a predetermined input from said pressure sensor;

securing said electrically-actuable wellbore tool, said pressure sensor, and said programmable controller to a tubular conduit string;

lowering said tubular conduit string within said wellbore to a selected wellbore location;

providing a wellbore fluid column in contact with a portion of said tubular conduit but out of contact with said pressure sensor;

manipulating pressure of said wellbore fluid column in a predetermined manner to generate a series of transient rapid pressure amplitude changes above a predetermined rate-of-change threshold to stimulate said pressure sensor through said tubular conduit string to produce said predetermined input, without substantially changing volume of said wellbore fluid column; and

detecting said series of transient rapid pressure amplitude changes through elastic deformation of a rigid structural component utilizing said pressure sensor;

utilizing said programmable processor to provide said predetermined output to switch said electrically-actuable wellbore tool between modes of operation.

18. A method according to claim 17, further comprising:

providing a pressure pulse generator in communication with said fluid column;

wherein said step of manipulating pressure comprises manipulating pressure of said wellbore fluid column in a predetermined manner utilizing said pressure pulse generator to generate a series of transient rapid pressure amplitude changes above a predetermined rate-of-change threshold in accordance with at least one of the following techniques;

(a) generating positive pressure pulses by rapidly injecting small volumes of fluid into said wellbore fluid column; and

(b) generating negative pressure pulses by rapidly venting small volumes of fluid from said wellbore fluid column;

to stimulate said pressure sensor through said tubular conduit string to produce said predetermined input without substantially changing volume of said wellbore fluid column.

19. A method according to claim 17, further comprising:

providing a fluid body in contact with (a) said tubular conduit string and (b) said pressure sensor, but out of contact with said wellbore fluid column, to transfer pressure changes between (a) said tubular conduit string and (b) said pressure sensor.

20. A method according to claim 17, further comprising:

maintaining said programmable controller in a off condition until at least one rapid pressure amplitude change above said predetermined rate-of-change threshold is detected by said pressure sensor.

21. A method according to claim 20, further comprising:

returning said programmable controller to an off condition if at least one of the following conditions occur;

(a) detected rapid pressure amplitude changes fail to define a coded message;

(b) additional rapid pressure amplitude changes do not occur within a predetermined time interval.

22. A method according to claim 17, wherein said step of manipulating pressure, rapid pressure amplitude changes are monitored without regard to pressure amplitude of said wellbore fluid column.

23. An apparatus for communicating a coded message in a wellbore between a transmission node and a reception node, through a fluid column extending therebetween, comprising:

a transmission apparatus at said transmission node which is in communication with said fluid column, for generating an acoustic pressure pulse to produce at least a portion of said coded message;

a reception apparatus at said reception node which includes;

(a) a rigid structural component with an exterior surface which is in contact with said fluid column and an interior surface which is not in contact with said fluid column;

(b) a sensor assembly which detects changes in elastic deformation of said rigid structural component;

wherein, during a communication mode of operation;

(a) said transmission apparatus is utilized to alter pressure of said fluid column in a predetermined pattern to generate said coded message; and

(b) said reception apparatus is utilized to detect said coded message in said fluid column through changes in elastic deformation of said rigid structural component.

24. A method according to claim 23, wherein said sensor assembly includes a fluid body which is in communication with said interior surface of said rigid structural component, but which is not in communication with said fluid column, and which is responsive to said changes in elastic deformation of said rigid structural component.

25. A method according to claim 24, wherein said sensor assembly further includes a pressure sensor within said fluid body for directly sensing pressure changes in said fluid body to detect elastic deformation of said rigid structural component.

26. A method according to claim 23, wherein said sensor assembly includes at least one strain sensor which is coupled to said interior surface of said rigid structural component and which is responsive to changes in elastic deformation of said rigid structural component.

27. A method according to claim 23, wherein said rigid structural component of said reception apparatus comprises a mandrel member which at least partially defines a central bore through a wellbore tubular member.

28. An apparatus according to claim 23, further comprising:

a processor programmed to identify particular input electrical signal patterns with particular predefined processor tasks;

wherein, during said communication mode of operation;

(a) electrical signals are generated with said reception apparatus which correspond to changes in elastic deformation of said rigid structural component and are directed to said processor as an input; and

(b) said processor is utilized to perform said particular predefined processor tasks in response to detection of particular electrical signal patterns.

29. An apparatus according to claim 23:

wherein said particular electrical signal patterns define said coded message with operator-selectable coded message attributes of;

(a) number of consecutive electrical signals, each corresponding to an elastic deformation of said rigid structural component; and

(b) time between consecutive electrical signals;

which distinguish one particular coded messages from other coded messages.

30. An apparatus according to claim 28, further including:

a programming unit;

a programming interface in electrical communication with said processor; and

wherein, during a programming mode of operation said programming unit and said programming interface are utilized to program said processor to provide a particular output in response to receipt of a particular electrical signal pattern from said reception apparatus.

31. An apparatus according to claim 30:

wherein said reception apparatus includes a plurality of power-consuming electrical components including said processor;

wherein, during a communication mode of operation at least a portion of said power-consuming electrical components are maintained in an off condition until at least one signal is received at said programming interface.

32. An apparatus according to claim 31, wherein, during said communication mode of operation said at least a portion of said power-consuming electrical components are returned to said off condition if no additional signals are received at said programming interface within a predetermined time interval.

33. An apparatus according to claim 23:

wherein said sensor assembly generates electrical signals corresponding to elastic deformation of said rigid structural component;

wherein said reception apparatus further includes a signal processor for identifying and isolating rates of change in elastic deformation of said rigid structural component which correspond to rates of change in fluid pressure amplitude of said fluid column above a predetermined rate threshold; and

wherein, during said communication node of operation, said reception apparatus is utilized to detect said coded message in said fluid column through monitoring of rates of change in fluid pressure amplitude of said fluid column as detected by elastic deformation of said rigid structural component.

34. An apparatus according to claim 23:

wherein said reception apparatus includes a plurality of power-consuming electrical components; and

wherein, during said communication node of operation, at least a portion of said power-consuming electrical components are maintained in an off condition until said reception apparatus detects at least one change in elastic deformation of said rigid structural component.

35. An apparatus according to claim 34, wherein, during said communication node of operation, said at least a portion of said power-consuming electrical components are returned to said off condition if at least one of the following conditions occur:

(a) detected changes in elastic deformation fail to define a coded message; and

(b) additional changes in elastic deformation do not occur within a predetermined time interval.

36. An apparatus for communicating a coded message in a wellbore between a transmission node and a reception node, through a fluid column extending therebetween, comprising:

a transmission apparatus at said transmission node which is in communication with said fluid column for applying a series of pressure impulses to said fluid column, each pressure impulse creating a temporary change in fluid pressure amplitude in said fluid column without substantially changing the volume of said fluid column;

a reception apparatus at said reception node which includes a sensor assembly for detecting elastic deformation caused by each temporary change in fluid pressure amplitude for each pressure impulse;

wherein, during a communication mode of operation;

(a) said transmission apparatus is utilized to generate said pressure impulses in a predetermined pattern to generate said coded message; and

(b) said reception apparatus is utilized to detect said coded message.

37. An apparatus for communicating coded messages in a wellbore according to claim 36, wherein, during said communication mode of operation, for each pressure impulse, said transmission apparatus injects a known volume of fluid into said fluid column at a high velocity.

38. An apparatus for communicating a coded message in a wellbore according to claim 36, wherein said transmission apparatus comprises:

a driver apparatus for receiving a known volume of fluid during a filling mode of operation and for rapidly discharging said known volume of fluid during a discharge mode of operation; and

means for providing an uninterrupted fluid body from said driver apparatus to said fluid column.

39. An apparatus for communicating in a wellbore between a transmission node and a reception node, through a fluid column extending therebetween, comprising:

a transmission apparatus at said transmission node which is in communication with said fluid column for applying a series of pressure impulses to said fluid column to generate a coded message, each coded message being defined by the following operator-selectable coded message attributes;

(a) number of consecutive pressure impulses; and

(b) time between consecutive pressure impulses;

a reception apparatus, at said reception node, for detecting said coded messages;

wherein, during a communication mode of operation;

(a) said transmission apparatus is utilized to generate said pressure impulses in a predetermined pattern to generate said coded message; and

(b) said reception apparatus is utilized to detect said coded message through monitoring of elastic deformation of a structural component.

40. An apparatus for communicating in a wellbore, according to claim 39:

wherein a plurality of reception apparati are provided, each located at a reception node;

wherein each reception apparatus is preprogrammed to be responsive to at least one coded message.