Apparatus and method for performing imaging and downhole operations at a work site in wellbores

• US 6,041,860 A
• Filed: 07/16/1997
• Issued: 03/28/2000
• Est. Priority Date: 07/17/1996
• Status: Expired due to Term

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Nazzal, Gregory R., Lynde, Gerald D., Leggett, James V. III, Tubel, Paulo S., Harrell, John W.
• Primary Examiner(s): NEUDER, WILLIAM P
• Application Number:
  US08/893,312
• Time in Patent Office: 986 Days
• Field of Search: 166/250.01, 166/253.1, 166/255.2, 166/250.08, 166/250.09, 166/250.17, 166/55.1, 166/66, 166/222, 166/223, 73/152.01, 73/152.17
• US Class Current: 166/250.01
• CPC Class Codes: E21B 23/12 Tool diverters
• CPC Class Codes: E21B 29/00 Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
• CPC Class Codes: E21B 29/06 Cutting windows, e.g. directional window cutters for whipstock operations E21B29/005 and E21B29/08 take precedence
• CPC Class Codes: E21B 29/10 Reconditioning of well casings, e.g. straightening
• CPC Class Codes: E21B 31/14 with means deflecting the direction of the tool, e.g. by use of knuckle joints
• CPC Class Codes: E21B 33/124 Units with longitudinally-spaced plugs for isolating the intermediate space
• CPC Class Codes: E21B 33/1243 with inflatable sleeves
• CPC Class Codes: E21B 33/127 with inflatable sleeve E21B33/122, E21B33/124 take precedence
• CPC Class Codes: E21B 33/134 Bridging plugs
• CPC Class Codes: E21B 33/138 Plastering the borehole wall; Injecting into the formation
• CPC Class Codes: E21B 41/0035 Apparatus or methods for multilateral well technology, e.g. for the completion of or workover on wells with one or more lateral branches
• CPC Class Codes: E21B 41/0078 Nozzles used in boreholes drilling by liquid or gas jets E21B7/18; drill bits with nozzles E21B10/60; perforators using direct fluid action E21B43/114; obtaining a slurry of minerals using nozzles E21B43/29
• CPC Class Codes: E21B 43/114 Perforators using direct fluid action on the wall to be perforated, e.g. abrasive jets
• CPC Class Codes: E21B 47/00 Survey of boreholes or wells monitoring pressure or flow of drilling fluid E21B21/08
• CPC Class Codes: E21B 47/002 by visual inspection
• CPC Class Codes: E21B 49/08 Obtaining fluid samples or testing fluids, in boreholes or wells

Abstract

The present invention provides a downhole service tool for imaging a location constituting a work site of interest downhole at which a tool operation is to be performed in a preexisting wellbore and for performing a tool operation at the work site during a single trip of the tool, The downhole service tool includes an imaging device which sensors properties associated with the work site and generates data representative of the work site. The imaging date is transmitted to the surface via a two-way telemetry system. An end work device in the downhole service tool performs the desired tool operation at the desired work site. The service tool images the work site, communicates imaging data to the surface and performs the desired operation during a single trip into the wellbore.

Claims

1. A downhole tool for imaging a work site within a pre-existing wellbore and performing a tool operation at the work site during a single trip of the downhole tool in the wellbore, the downhole tool comprising;

(a) an imaging device carried by the downhole tool for imaging the work site; and

(b) a work device carried by the downhole tool for performing the tool operation at the work site;

whereby the downhole tool obtains the image of the work site and performs the tool operation at the work site during a single trip of the downhole tool into the wellbore.

2. The downhole tool of claim 1, wherein the imaging device is selected from a group consisting of a camera for optical viewing, an acoustic device, an ultrasonic device, an infra-red device, an RF device, a microwave device, a contacting device, a tactile device, and a fiber optic device.

3. The downhole tool of claim 1, further comprising a transmitter for transmitting data of the image of the work site to a surface location.

4. The downhole tool of claim 1, wherein the imaging device is a contacting device comprising at least one projection extending from the downhole tool that contacts with the work site to obtain the image of the work site.

5. The downhole tool of claim 3, wherein the transmitter is selected from a group consisting of an electromagnetic transmitter, a fluid acoustic transmitter, a tubular fluid transmitter, a mud-pulse transmitter, a fiber optic transmitter, and a conductor wire transmitter.

6. The downhole tool of claim 1, wherein the work device is selected from a group consisting of a fishing tool to engage with a fish, a whipstock, a diverter, a re-entry tool, an anchor, a packer, a seal, an inflatable packer, a plug, a perforating tool, a fluid stimulation tool, an acidizing tool, a fluid fracturing tool, a milling tool, a cutting tool, a patch tool, a drilling tool, a cladding tool, a welding tool, a deforming tool, a sealing tool, a cleaning tool, a device for installing a device in the wellbore, a device for removing a device downhole, a testing device for performing a test in the wellbore, an inspection device, and a tool for engaging with a downhole object to perform a desired operation.

7. The downhole tool of claim 1 further comprising a computer having at least one processor for controlling the operation of the work device.

8. The downhole tool of claim 1, wherein the work device is movable radially and longitudinally relative to the wellbore.

9. The downhole tool of claim 1 further comprising a memory device for recording data of the image of the work site for retrieval when the downhole tool is brought out of the wellbore.

10. The downhole tool of claim 1 further comprising a memory device containing work site data, said downhole tool correlating data generated by the downhole tool with the work site data to facilitate identification of the image of the work site.

11. The downhole tool of claim 10, wherein a transmitter in said downhole tool generates signals for transmission to a surface location representative of the data of the work site generated by the downhole tool.

12. The downhole tool of claim 11, wherein the transmitter communicates with other equipment in the wellbore.

13. The downhole tool of claim 1 further comprising a receiver for receiving signals sent from a surface location to the downhole tool.

14. The downhole tool of claim 1 further comprising a formation evaluation sensor for providing measurements of a parameter of interest of the formation surrounding the wellbore.

15. The downhole tool of claim 1 further comprising at least one sensor for determining an operating condition of the downhole tool, said operating condition being one of temperature, pressure, fluid flow, tool orientation, pull force, gripping force, tool centerline position, tool configuration, inclination, and acceleration.

16. The downhole tool of claim 1, wherein the imaging device obtains image of an object positioned downhole of the downhole tool.

17. The downhole tool of claim 1, wherein the imaging device is an ultrasonic device to provide image of the work site located downhole of the downhole tool.

18. The downhole tool of claim 17, wherein the ultrasonic device includes at least one transmitter for transmitting signals to the work site downhole of the downhole tool and a receiver for receiving signals reflected by the work site in response to the transmitted signals.

19. The downhole tool of claim 18, wherein the imaging device operates the transmitter by sweeping a preselected frequency range to obtain an effective operating frequency and continues to operate the transmitter at such effective frequency to generate data representative of attributes of the work site.

20. The downhole tool of claim 1, wherein the imaging device is beam-steered to generate data representative of the properties of the work site.

21. The downhole tool of claim 1, wherein the imaging device includes a sensor that is rotated to generate data representative of the properties of the work site.

22. The downhole tool of claim 1, wherein the work device is a cutting device that performs cutting with a high pressure fluid.

23. The downhole tool of claim 1, wherein the work device is a reentry device that includes an orienting device that can be oriented to cause the reentry device to enter into a lateral wellbore intersecting the wellbore.

24. The downhole tool of claim 23, wherein the orienting device is selected from a group of devices consisting of a knuckle joint, a flexible joint that is operated by a control circuit in the downhole tool, a flexible joint that is remotely operable, and a deflection device that re-orients the downhole tool when said deflection device is urged against the wellbore.

25. The downhole tool of claim 1 further comprising two spaced-apart isolators, said isolators isolating a zone of interest in the wellbore.

26. The downhole tool of claim 25 further comprising a device for injecting fluid into the zone of interest to perform testing of the zone of interest.

27. The downhole tool of claim 25, wherein the isolated zone is selected from the group consisting of a perforated zone, and juncture between the wellbore and a lateral wellbore.

28. The downhole tool of claim 1, wherein the imaging device is a tactile device having at least one probe that extends from the downhole tool to make contact with the work site to provide signals representative of a physical attribute of the work site.

29. A method of imaging a location constituting a work site of interest at which a tool operation is to be performed in a pre-existing wellbore and performing a work at the work site during a single trip, comprising:

(a) conveying a downhole tool with a tubing extending from a surface location down into the wellbore, said downhole tool carrying a sensor adjacent a lower end of the tool for sensing properties associated with the image of the work site and generating data representative of the image of the work site, a transmitter transmitting signals representative of the data to the surface location and an end work device for performing the tool operation;

(b) positioning the tool adjacent the work site;

(c) sensing properties associated with an image of the work site downhole;

(d) generating data representative of the image of the work site;

(e) transmitting the data to the surface location; and

(f) performing the tool operation at the work site [location during the single trip of the downhole tool into the wellbore.

30. A method of imaging a work site and performing an end work at the work site in a pre-existing wellbore during a single trip into the wellbore, comprising:

(a) conveying a downhole tool into the wellbore, said downhole tool having an imaging device for imaging a work site in the wellbore, a device for isolating the work site, and an end work device for performing a desired work at the work site;

(b) isolating the work site;

(c) imaging the work site by the imaging device; and

(d) operating the end work device to perform a desired operation at the work site during the single trip of the downhole tool into the wellbore.

31. A method of imaging a location constituting a work site of interest in a preexisting wellbore at which a desired operation is to be performed without removing the tool from the wellbore, comprising:

(a) positioning a downhole tool adjacent the work site, said downhole tool having an imaging device for sensing properties associated with the work site and generating data representative of the work site, a transmitter for receiving the data and transmitting signals representative of the data to a surface location and an end work device for performing the desired tool operation;

(b) generating data representative of the work site and transmitting signals representative of the data to the surface location by the transmitter; and

(c) performing the desired tool operation at the work site location during a single trip of the tool into the wellbore.

32. A downhole oilfield service tool for imaging a work site in a wellbore and for performing a desired operation at the work site without requiring retrieving of the service tool from the wellbore prior to performing the desired operation, said service tool conveyable into the wellbore by a tubing extending from a surface location toward and adjacent the work site, comprising:

(a) an ultrasonic sensor adjacent a lower end of the tubing for providing an image of the work site and generating data representative of said image;

(b) a transmitter associated with the service tool for receiving the data generated by the sensor and transmitting signals representative of said data to the surface; and

(c) a milling tool adjacent the lower end of the tubing for performing the desired operation at the work site based at least partially upon said data without retrieving the service tool from the wellbore prior to performing the desired operation.

33. A downhole service tool for entry into a branch wellbore from a juncture at a main wellbore to perform an end work at a work site in the branch wellbore during a single trip into the main wellbore, comprising:

(a) a sensor adapted to obtain data for an image of the juncture;

(b) a control circuit in the service tool for receiving the data from the sensor and transmitting signals representative of said data to the surface to obtain the image of the juncture;

(c) a tool orientation device in the service tool, said device adapted to be operated downhole by the control circuit, to cause the service tool to enter the branch wellbore; and

(d) an end work device for performing the end work at the work site in the branch wellbore, whereby the service tool can locate the juncture, enter into the branch wellbore from the main wellbore and perform the desired operation at the work site in a single trip.

34. The downhole service tool of claim 33, wherein the tool orientation device is selected by a group consisting of a knuckle joint that is controlled from a command signal from the surface, a knuckle joint that is controlled downhole, a plurality of independently adjustable pads, and a member that extends outward from the service tool to urge against the wellbore to cause the service tool to move transverse to the wellbore axis.

35. A downhole service tool for imaging a selected work site in a wellbore and performing a welding operation at the selected work site in a wellbore during a single trip, comprising:

(a) a sensor adapted to obtain data to image the work site;

(b) a control circuit in the service tool for receiving the data from the sensor and transmitting signals representative of said data to the surface to obtain the image of the work site; and

(c) a welding device in the service tool, said welding device adapted to be operated downhole by the control circuit to perform the welding operation at the work site during the single trip.

36. The downhole service tool of claim 35, wherein the selected work site is selected from a group consisting of a joint between casing in a main wellbore and a branch wellbore formed from the main wellbore and a packer.

37. A downhole oilfield service tool conveyable into a wellbore for imaging a location constituting a work site of interest downhole and performing a testing operation at the work site during a single trip of the tool in the wellbore, the tool comprising;

(a) a sensor for sensing properties associated with the desired work site in the wellbore and generating data representative of the work site;

(b) a transmitter for receiving the data from the sensor and transmitting signals representative of said data to the surface; and

(c) a pair of spaced apart seals on the service tool to seal at least a portion of the work site of interest between the pair of seals; and

(d) a testing device in the tool to perform a selected test in the sealed work site, during the single trip.

38. The downhole service tool of claim 37, wherein the selected work site is a perforated zone.

39. The downhole service tool of claim 38, wherein the testing device performs a test selected from a group consisting of pressure test of a sealed region, pressure build-up over a time period, temperature test, temperature build-up over a time period, reservoir analysis, formation evaluation, resistivity of formation fluids, sample collection, formation fluid analysis, and hydrocarbon content of formation fluids.

40. A downhole tool conveyable into a wellbore for imaging a location constituting a work site of interest downhole and performing a workover operation at the work site during a single trip of the tool in the wellbore, the downhole tool comprising;

(a) a sensor for sensing properties associated with the image of the work site in the wellbore and generating data representative of the image of the work site;

(b) a transmitter for receiving the data from the sensor and transmitting signals representative of said data to the surface; and

(c) a pair of spaced-apart seals on the service tool to seal at least a portion of the work site of interest between the pair of seals; and

(d) a device for injecting a pressurized fluid into the sealed portion of the work site to perform the workover operation, during the single trip of the downhole tool into the wellbore.

41. The downhole service tool of claim 40, wherein the work site of interest is a perforated region and the sealed portion includes at least one perforation.

42. The downhole service tool of claim 41, wherein the fluid is selected from a group consisting of cement slurry, polymer, water, steam, chemicals, and acidizing fluids.

43. The downhole service tool of claim 40, wherein the workover operation is selected from the group consisting of injecting fluids into a perforated zone to improve hydrocarbon production, sealing of a zone to prevent production of fluids therefrom, cementing, fracturing, and cleaning.

48. The imaging tool of claim 43 further having a control circuit within the imaging tool for automatically controlling the operation of the fluid injection system and for operating the camera to obtain the desired image of the work site according to programmed instructions provided to the control circuit.

50. The imaging tool of claim 43, wherein the fluid injection system comprises:

(i) a source of substantially transparent fluid; and

(ii) a fluid transfer mechanism for displacing the at least a portion of the substantially non-transparent fluid with the substantially transparent fluid wellbore.

53. The imaging tool of claim 43, wherein the device for providing the seal is a packer.

44. An imaging tool for obtaining an image of a work site in a wellbore, said wellbore having wellbore fluid therein, the imaging tool comprising:

(a) a fluid injection system for displacing wellbore fluid adjacent the work site with a substantially transparent fluid; and

(b) a camera associated with the imaging tool for taking an image of the work site.

45. The imaging tool of claim 44, wherein the imaging tool is conveyable into the wellbore by a conveying device selected from a group consisting of a wireline, a tubing and a traction device that can move the imaging tool through the wellbore.

46. The imaging tool of claim 44, wherein the camera is adapted to be remotely oriented in a desired direction to take an image of the work site.

47. The imaging tool of claim 44 further having a control unit at the surface coupled to said imaging tool for receiving data from the camera and for displaying the image of the work site.

49. The imaging tool of claim 44 further having a control circuit within the imaging tool for controlling the operation of the fluid injection system and for operating the camera to obtain the image of the work site according to instructions provided to the control circuit.

51. The imaging tool of claim 44, wherein the fluid injection system comprises:

(i) a source of substantially transparent fluid; and

(ii) a fluid transfer mechanism for displacing at least a portion of the wellbore fluid with the substantially transparent fluid.

52. The imaging tool of claim 51 further having a fluid communication line coupled to a fluid chamber for retrieving the substantially transparent fluid from the wellbore into the fluid chamber.

54. The imaging tool of claim 44, further comprising a seal for isolating wellbore fluid adjacent said work site.

55. A method for imaging a work site of interest located within a wellbore containing a substantially non-transparent fluid therein, said method comprising:

(a) conveying an imaging tool within the wellbore to a location above the work site;

(b) isolating utilizing at least one seal the work site;

(c) displacing the substantially non-transparent fluid in the work site with a substantially transparent fluid; and

(d) obtaining an image of the work site with the imaging tool.

56. A method for imaging a work site located within a wellbore containing a substantially non-transparent fluid therein, said method comprising:

(a) conveying an imaging tool within the wellbore to a location adjacent the work site;

(b) isolating the work site with a seal in the wellbore;

(c) displacing the substantially non-transparent fluid in the work site with a substantially transparent fluid; and

(d) obtaining an image of the work site with the imaging tool.

57. The method of claim 56 further comprising communicating the image of the work site to a surface location.

59. The imaging tool of claim 57, wherein the computer is located within the imaging tool for computing the image of the work site downhole during operation of the imaging tool.

61. The imaging tool of claim 57 further having a fluid injection system for injecting a fluid into the inflatable flexible device.

58. An imaging tool for obtaining an image of a work site within a wellbore, comprising:

(a) a tool body conveyable into the wellbore;

(b) a flexible inflatable device on the tool body having a plurality of spaced sensors arranged at a plurality of predetermined surface locations on the inflatable flexible device, each such sensor providing a signal in response to deformation of the surface locations of the flexible inflatable device at which such sensor is placed relative to a predetermined norm for such sensor; and

(c) a computer, said computer receiving signals from the sensors in the plurality of sensors when the inflatable flexible device is inflated and urged against the work site and in response thereto providing an image of the work site.

60. The imaging tool of claim 58, wherein the computer is located within the imaging tool for computing the image of the work site downhole.

62. A downhole oilfield service tool for imaging a work site in a wellbore and for performing a desired operation at the work site during a single trip of the service tool conveyed into the wellbore by a tubing extending from a surface location toward and adjacent to the work site, comprising:

(a) an imaging device adjacent a lower end of the tubing for providing an image of the work site; and

(b) an end work device adjacent the lower end of the tubing for performing the desired operation at the work site based at least partially upon the image of the work site during the single trip of the service tool in the wellbore.