Subterranean well completion incorporating downhole-parkable robot therein

• US 6,953,094 B2
• Filed: 09/24/2002
• Issued: 10/11/2005
• Est. Priority Date: 06/19/2002
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Wohleb, Clifford David Jr., Ross, Colby Munro, Hamid, Syed, Thurman, Robert L., McGregor, Ronald W.
• Primary Examiner(s): DANG, HOANG C
• Application Number:
  US10/253,061
• Publication Number:
  US 20040055746A1
• Time in Patent Office: 1,113 Days
• Field of Search: 166/381, 166/65.1, 166/50, 166/313
• US Class Current: 166/381
• CPC Class Codes: B23K 3/0623 for shaped solder piece feeding, e.g. preforms, bumps, balls, pellets, droplets
• 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 23/001 Self-propelling systems or apparatus, e.g. for moving tools within the horizontal portion of a borehole
• CPC Class Codes: E21B 23/03 for setting the tools into, or removing the tools from, laterally offset landing nipples or pockets
• CPC Class Codes: E21B 34/14 operated by movement of tools, e.g. sleeve valves operated by pistons or wire line tools E21B34/066 takes precedence
• CPC Class Codes: G01V 11/002 Details, e.g. power supply systems for logging instruments, transmitting or recording data, specially adapted for well logging, also if the prospecting method is irrelevant means for transmitting well survey signals E21B47/12; signal transmission systems in general G08C; transmission in general H04B

Abstract

A subterranean well completion has a tubular structure in which a remote controlled robot is permanently disposed. The robot is self-propelled, programmable, receives instructions from and communicates data to the surface, and is adapted to receive power from a downhole source and perform a variety of well tasks such as, for example, positioning valves and other well tools and sensing the values of predetermined downhole parameters and relaying the sensed information to the surface. The robot, which is operable without physical intervention through the tubular structure to the robot, propels itself to a location in the tubular structure at which a desired well task is to be performed, performs the task and then parks itself in the tubular structure until another well task is to be performed by the robot.

Claims

1. A subterranean well completion comprising:

a tubular structure extending through the earth; and

a remote controlled robot disposed in the tubular structure and being capable of performing downhole well tasks, the robot being operable to utilize power from a source thereof to propel itself along the interior of the tubular structure, perform a predetermined downhole well task; and

then park within the tubular structure until another well task is to be performed by the robot, the source of power including a power structure carried by the robot, the power structure being a rechargeable electric battery and further including downhole electrical recharging apparatus, the robot being selectively associateable with the recharging apparatus in a manner permitting the rechargeable battery to be recharged by the electrical recharging apparatus,

the downhole electrical recharging apparatus being operative to recharge the rechargeable electric battery in response to movement of the robot to a predetermined position relative to a portion of the down hole electrical recharging apparatus.

2. A subterranean well completion comprising:

a tubular structure extending through the earth; and

a remote controlled robot disposed in the tubular structure and being capable of performing downhole well tasks, the robot being operable to utilize power from a source thereof to propel itself along the interior of the tubular structure, perform a predetermined down hole well task; and

then park within the tubular structure until another well task is to be performed by the robot, the source of power including a power structure carried by the robot, the power structure being a rechargeable electric battery and further including downhole electrical recharging apparatus, the robot being selectively associateable with the recharging apparatus in a manner permitting the rechargeable battery to be recharged by the electrical recharging apparatus,

the robot having a charging signal generating structure, and

the downhole electrical recharging apparatus being operative to recharge the rechargeable electric battery, in response to generation of a charging signal by the robot, when the robot is positioned adjacent a predetermined portion of the downhole electrical recharging apparatus, and terminate the recharging in response to cessation of the charging signal.

3. A subterranean well completion comprising:

a tubular structure extending through the earth; and

a remote controlled robot disposed in the tubular structure and being capable of performing downhole well tasks, the robot being operable to utilize power from a source thereof to propel itself along the interior of the tubular structure, perform a predetermined downhole well task; and

then park within the tubular structure until another well task is to be performed by the robot, the source of power including a power structure carried by the robot, the power structure being a rechargeable electric battery and further including downhole electrical recharging apparatus, the robot being selectively associateable with the recharging apparatus in a manner permitting the rechargeable battery to be recharged by the electrical recharging apparatus, the downhole electrical recharging apparatus including docking structure carried by the tubular structure and to which the robot may be docked while its battery is being recharged by the downhole electrical recharging apparatus,

the docking structure being operative, when the robot is docked thereto, to generate an output signal, which may be transmitted to the surface, indicative of the location of the robot within the tubular structure.

4. A subterranean well completion comprising:

a tubular structure extending through the earth; and

a remote controlled robot disposed in the tubular structure and having a work structure, the robot being operable to utilize power from a source thereof to propel itself along the interior of the tubular structure to a location therein at which a predetermined well task is to be performed, activate the work structure to perform the predetermined well task, and then park in the tubular structure until needed to perform another well task,

the robot having a retractible external driving structure operable to propel the robot in opposite directions along the length of the interior of the tubular structure,

the tubular structure having first and second adjacent longitudinal portions with different interior diameters, and

the driving structure being adapted to permit the robot to move between the first and second longitudinal portions and operate in either of them.

5. The subterranean well completion of claim 4 wherein:

the tubular structure Is a length of production tubing.

6. The subterranean well completion of claim 4 wherein:

the tubular structure is a length of casing.

7. The subterranean well completion of claim 4 wherein:

the robot is operable to park itself at a location in the tubular structure remote from the location therein at which the robot performed the predetermined well task.

8. The subterranean well completion of claim 4 further comprising:

cooperatively and releasably engageable locating structures on the robot and the tubular structure.

9. The subterranean well completion of claim 8 wherein:

the cooperatively and releasably engageable locating structures include a locating profile interiorly disposed on the tubular structure.

10. The subterranean well completion of claim 4 wherein:

the robot is operable without physical intervention into the tubular structure between the surface and the robot.

11. The subterranean well completion of claim 4 wherein:

the tubular structure is operative to permit fluid flow therethrough, and

the robot is configured in a manner such that it laterally blocks no more than about eighty percent of the fluid flow area within the tubular structure.

12. A subterranean well completion comprising:

a tubular structure extending through the earth; and

a remote controlled robot disposed in the tubular structure and having a work structure, the robot being operable to utilize power from a source thereof to propel itself along the interior of the tubular structure to a location therein at which a predetermined well task is to be performed, activate the work structure to perform the predetermined well task, and then park in the tubular structure until needed to perform another well task,

the tubular structure being operative to permit fluid flow therethrough,

the robot being configured in a manner such that it laterally blocks no more than about eighty percent of the fluid flow area within the tubular structure, and

the robot having opposite open ends spaced apart along the axis of the tubular structure, and an interior through which the opposite open ends communicate.

13. A subterranean well completion comprising:

a tubular structure extending through the earth, the tubular structure having a powering structure adapted to receive electrical power from the earth'"'"'s surface;

a remote controlled, self-propelled, work-performing robot disposed in the tubular structure and being powered by an onboard rechargeable battery, the robot having a power receiving portion positionable relative to the powering structure to receive electrical power therefrom to recharge the battery; and

communication apparatus operative to provide information communication between the earth and the robot,

the operation of the robot being programmable, and wherein the robot may be reprogrammed via the communication apparatus,

the well completion further comprising a downhole sensor separate from the robot and operative to sense the value of a downhole parameter, and

the robot further having a sensor detection portion operative to retrieve from the sensor the sensed value of the parameter and transmit the sensed value to the surface via the communication apparatus.

14. The subterranean well completion of claim 13 wherein:

the power receiving portion is inductively coupleable to the powering structure.

15. The subterranean well completion of claim 13 further comprising:

electrical power supply wiring extending to the surface from the powering structure.

16. The subterranean well completion of claim 13 wherein:

the robot further has a sensor disposed thereon, the sensor being operative to sense the value of a predetermined downhole parameter and transmit the value of the sensed parameter to the surface via the communication apparatus.

17. The subterranean well completion of claim 13 wherein:

the communication apparatus includes communication structure carried by the robot, and associated communication structure carried by the tubular structure.

18. The subterranean well completion of claim 17 wherein:

the communication structure carried by the tubular structure is connected to the surface by fiber optic cable.

19. The subterranean well completion of claim 13 wherein:

the communication apparatus includes communication structure carried by the robot and providing it with wireless communication with the surface.

20. The subterranean well completion of claim 13 wherein:

the downhole sensor is mounted on the tubular structure.

21. The subterranean well completion of claim 13 wherein:

the robot is programmable and is pre-programmed to autonomously perform at least one downhole well task.

22. The subterranean well completion of claim 13 wherein:

the tubular structure is a length of production tubing.

23. The subterranean well completion of claim 13 wherein:

the tubular structure is a length of casing.

24. The subterranean well completion of claim 13 wherein:

the robot is operative to perform a predetermined well task within the tubular structure.

25. The subterranean well completion of claim 24 wherein:

the robot is operative to park itself in the tubular structure, subsequent to the performance of the predetermined well task, until a second well task is to be performed within the tubular structure.

26. The subterranean well completion of claim 25 wherein:

the robot is operative to park itself at a location in the tubular structure spaced apart along the length of the tubular structure from the location of the predetermined well task.

27. The subterranean well completion of claim 13 wherein:

the powering structure includes a spaced plurality of powering structures spaced apart along the length of the tubular structure, and

the robot is positionable within the tubular structure to sequentially receive electrical power from the powering structures.

28. The subterranean well completion of claim 27 wherein:

the powering structures include docking structures with which the robot is engageable to park the robot within the tubular structure.

29. The subterranean well completion of claim 27 wherein:

each powering structure is operative to transmit a signal to the communication portion indicating that the robot is receiving power from the powering structure, the signal thereby being indicative of the position of the robot within the tubular structure.

30. A subterranean well completion comprising:

a tubular structure extending through the earth, the tubular structure having a powering structure adapted to receive electrical power from the surface;

a remote controlled, self-propelled, work-performing robot disposed in the tubular structure and being powered by an onboard rechargeable battery, the robot having a power receiving portion positionable relative to the powering structure to receive electrical power therefrom to recharge the battery; and

communication apparatus operative to provide information communication between the earth and the robot,

the tubular structure having first and second adjacent longitudinal portions having different interior diameters, and

the robot having a retractible exterior propulsion structure enabling the robot to enter either longitudinal portion from the other longitudinal portion and perform work in the entered portion of the tubular structure.

31. A method of operating a subterranean well completion having a tubular structure extending through the earth, the method comprising the steps of:

providing a remote controlled, self-propelled robot;

disposing the robot within the tubular structure, the robot having an onboard rechargeable electric battery;

utilizing the robot to perform a first predetermined well task in the tubular structure at a predetermined location therein;

utilizing a downhole electrical power source to recharge the electric battery, the downhole electrical power source including a longitudinally spaced plurality of downhole electrical recharging stations carried by the tubular structure,

parking the robot within the tubular structure; and

then

causing the robot to perform a second predetermined well task in the tubular structure,

the robot being programmable, and

the method further comprising the step of programming the robot to access the closest recharging station to receive electrical power therefrom.

32. A method of operating a subterranean well completion having a tubular structure extending through the earth, the method comprising the steps of:

providing a remote controlled, self-propelled robot;

disposing the robot within the tubular structure, the robot having an onboard rechargeable electric battery;

utilizing the robot to perform a first predetermined well task in the tubular structure at a predetermined location therein;

utilizing a downhole electrical power source to recharge the electric battery, the downhole electrical power source including a longitudinally spaced plurality of downhole electrical recharging stations carried by the tubular structure,

parking the robot within the tubular structure; and

then

causing the robot to perform a second predetermined well task in the tubular structure,

the robot being operative to transmit a power requirement signal, and

the method further comprising the step of requiring the receipt of the power requirement signal by a recharging station before it can transmit electrical power to the robot.

33. A method of operating a subterranean well completion having a tubular structure extending through the earth, the method comprising the steps of:

providing a remote controlled, self-propelled robot;

disposing the robot within the tubular structure, the robot having an onboard rechargeable electric battery;

utilizing the robot to perform a first predetermined well task in the tubular structure at a predetermined location therein;

utilizing a downhole electrical power source to recharge the electric battery, the downhole electrical power source including a longitudinally spaced plurality of downhole electrical recharging stations carried by the tubular structure;

utilizing the operative association of the robot with one of the recharging stations to generate a signal indicative of the longitudinal position of the robot within the tubular structure;

parking the robot within the tubular structure; and

then

causing the robot to perform a second predetermined well task in the tubular structure.

34. A method of operating a subterranean well completion having a tubular structure extending through the earth, the method comprising the steps of:

providing a remote controlled, self-propelled robot;

disposing the robot within the tubular structure;

utilizing the robot to perform a first predetermined well task in the tubular structure at a predetermined location therein;

parking the robot within the tubular structure; and

then

causing the robot to perform a second predetermined well task in the tubular structure; and

configuring the robot in a manner such that, at its longitudinal position within the tubular structure, it blocks no more than about eighty percent of the flow area of the tubular structure,

the configuring step being performed by providing the robot with a hollow configuration in which its interior opens outwardly through open uphole and downhole ends thereof.

35. A method of operating a subterranean well completion having a tubular structure extending through the earth, the method comprising the steps of:

providing a remote controlled, self-propelled robot;

disposing the robot within the tubular structure;

utilizing the robot to perform a first predetermined well task in the tubular structure at a predetermined location therein;

parking the robot within the tubular structure; and

then

causing the robot to perform a second predetermined well task in the tubular structure,

the tubular structure having adjacent longitudinal portions with differing interior diameters, and

the method further comprising the step of configuring the robot in a manner such that it can enter either longitudinal portion from the other longitudinal portion and perform a well task in the entered longitudinal portion.

36. The method of claim 35 wherein:

the configuring step includes the step of providing the robot with a retractible external drive structure.