Apparatus and method for relieving annular pressure in a wellbore using a wireless sensor network

• US 9,816,373 B2
• Filed: 12/18/2013
• Issued: 11/14/2017
• Est. Priority Date: 12/19/2012
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Howell, David A., Morrow, Timothy I., Disko, Mark M., Deffenbaugh, Max
• Primary Examiner(s): NGUYEN, LAURA N
• Application Number:
  US14/432,970
• Publication Number:
  US 20150285065A1
• Time in Patent Office: 1,427 Days
• Field of Search: None
• CPC Class Codes: E21B 47/005 Monitoring or checking of cementation quality or level
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves

Abstract

An electro-acoustic system for downhole telemetry is provided herein. The system employs a series of communications nodes spaced along a string of casing within a wellbore. The nodes are placed within the annular region surrounding the joints of casing within the well-bore. The nodes allow for wireless communication between transceivers residing within the communications nodes and a topside communications node at the wellhead. More specifically, the transceivers provide for node-to-node communication up a wellbore at high data transmission rates for data indicative of a parameter within an annular region behind the string of casing. A method of evaluating a parameter within an annular region along a cased-hole wellbore is also provided herein. The method uses a plurality of data transmission nodes situated along the casing string which send signals to a receiver at the surface. The signals are then analyzed.

Claims

1. An acoustic telemetry system for monitoring a parameter along an annular region in a cased-hole wellbore, comprising:

a casing string disposed in the wellbore, with a cement sheath residing at least partially within the annular region formed between the casing string and a surrounding subsurface rock matrix along the casing string;

a topside communications node placed proximate a well head of the wellbore;

a plurality of subsurface communications nodes spaced along the wellbore and attached to a wall of the casing string, the subsurface communications nodes configured to transmit acoustic signals from node-to-node up the wellbore and to the topside communications node;

one or more sensors for sensing the parameter within the annular region, with each sensor being in electrical communication with an associated subsurface communications node; and

a receiver at the surface configured to receive at least one of electrical signals and acoustic signals from the topside communications node;

a processor in communication with the receiver for analyzing the received at least one of the electrical signals and the acoustic signals received at the receiver, the processor evaluating the integrity of the cement sheath by comparing attenuation of the received acoustic signals between pairs of subsurface communications nodes; and

wherein each of the subsurface communications nodes comprises;

a sealed housing;

an electro-acoustic transducer and associated transceiver also residing within the housing, with the transceiver being designed to relay the acoustic signals from node-to-node up the wellbore, with each acoustic signal including a packet of information that comprises an identifier for the subsurface communications node that originally transmitted the acoustic signal from node-to-node, and an acoustic waveform having an amplitude indicative of the parameter; and

an independent power source residing within the housing providing power to the transceiver.

2. The electro-acoustic telemetry system of claim 1, wherein:

the wellbore is a subsea wellbore;

the well head is located on a bottom of a body of water; and

the topside communications node is configured to transmit signals to the receiver.

3. The electro-acoustic telemetry system of claim 2, wherein the body of water is an ocean, a sea, a bay or a lake.

4. The electro-acoustic telemetry system of claim 2, wherein the topside communications node is in electrical communication with a cable for transmitting the electrical signals from the topside communications node to the receiver.

5. The electro-acoustic telemetry system of claim 2, wherein:

the topside communications node comprises a transceiver for transmitting wireless acoustic signals to the receiver; and

each packet of information comprises a plurality of separate tones.

6. The electro-acoustic telemetry system of claim 2, wherein:

the parameter is pressure; and

each of the sensors comprises a pressure sensor.

7. The electro-acoustic telemetry system of claim 2, further comprising:

a sliding sleeve along the casing string, the sliding sleeve being configured to open in response to a signal, thereby relieving annular pressure.

8. The electro-acoustic telemetry system of claim 7, wherein:

the signal to open the sliding sleeve is an actuation signal originating from the surface;

the sliding sleeve is located proximate an upper end of the casing string; and

the sliding sleeve is configured to receive an acoustic signal transmitted from the topside communications node, and through the subsurface communications nodes, node-to-node, to the sliding sleeve.

9. The electro-acoustic telemetry system of claim 7, wherein:

the signal to open the sliding sleeve is an acoustic signal originating in the wellbore; and

the sliding sleeve comprises an electro-acoustic transducer for converting the acoustic signal originating in the wellbore to an electrical signal for the sliding sleeve, and a processor for sending the electrical signal for the sliding sleeve as an actuation signal to open the sleeve.

10. The electro-acoustic telemetry system of claim 7, wherein the:

the sliding sleeve is associated with a pressure sensor; and

the signal to open the sliding sleeve is an electrical actuation signal received from the associated sensor that causes the sliding sleeve to open automatically.

11. The electro-acoustic telemetry system of claim 2, wherein:

the parameter is casing strain;

one or more of the sensors comprises a strain gauge; and

the electro-acoustic transceivers transmit signals up the wellbore representative of strain readings, node-to-node, as part of the packets of information.

12. The electro-acoustic telemetry system of claim 2, wherein:

the system further comprises a sliding sleeve proximate an upper end of the casing string, the sliding sleeve being configured to open in response to a signal, thereby relieving annular pressure;

the sliding sleeve is associated with a strain gauge; and

the signal to open the sliding sleeve is an electrical actuation signal received from the associated strain gauge that causes the sliding sleeve to open.

13. The electro-acoustic telemetry system of claim 12, wherein the sliding sleeve comprises a processor that compares a value of signals indicative of strain gauge with a baseline value, and sends the actuation signal if the value of the signal indicative of strain gauge exceeds the baseline value, causing the sliding sleeve to open automatically.

14. The electro-acoustic telemetry system of claim 2, wherein:

the parameter is the presence of cement in the annular region; and

each of the sensors comprises the electro-acoustic transducer and associated transceiver for sending and receiving the acoustic signals from node-to-node.

15. The electro-acoustic telemetry system of claim 14, wherein:

each of the packets of information comprises a plurality of separate tones;

the receiver comprises a processor; and

the processor at the receiver is programmed to identify amplitude values of the tones generated by each subsurface communications node indicative of the parameter, and compare those amplitude values to a baseline amplitude value.

16. The electro-acoustic telemetry system of claim 15, wherein the baseline amplitude value is (i) a previously stored amplitude value indicative of an amplitude value of a joint of casing having a continuous annular cement sheath, or (ii) a moving average of amplitude readings taken from a pre-designated number of communications nodes in proximity to a subject communications node.

17. The electro-acoustic telemetry system of claim 1, wherein the system is used in a wellbore associated with the production of hydrocarbons.

18. The electro-acoustic telemetry system of claim 1, wherein the subsurface communications nodes are spaced at 20 to 40 foot (6.1 to 12.2 meter) intervals.

19. The electro-acoustic telemetry system of claim 1, wherein the subsurface communications nodes transmit data in acoustic form at a rate exceeding 50 bps.

20. The electro-acoustic telemetry system of claim 1, wherein each of the electro-acoustic transceivers is designed to listen for tones that are selected to be within a frequency band where the acoustic signals from node to node are detectable at least two nodes away from a transmitting communications node.

21. The electro-acoustic telemetry system of claim 20, wherein:

each subsurface communications node is configured to listen for acoustic signals generated for a longer time than the time for which acoustic signals were generated by a previous subsurface communications node;

acoustic signals provide data that is modulated by a multiple frequency shift keying method where each tone is selected from an alphabet of at least 8 tones.

22. The electro-acoustic system of claim 2, wherein:

each of the sensors resides within the housings of a selected subsurface communications node; and

the electro-acoustic transducers within the selected subsurface communications nodes convert electrical signals from the sensors into acoustic signals for the associated transceivers.

23. The electro-acoustic telemetry system of claim 22, wherein acoustic signals provide data that is modulated by (i) a multiple frequency shift keying method, (ii) a frequency shift keying method, (iii) a multi-frequency signaling method, (iv) a phase shift keying method, (v) a pulse position modulation method, or (vi) an on-off keying method.

24. The electro-acoustic telemetry system of claim 1, wherein the subsurface communications nodes are attached to an outer wall of the casing string by (i) an adhesive material, (ii) welding, or (iii) one or more mechanical fasteners.

25. The electro-acoustic telemetry system of claim 1, wherein:

each of the subsurface communications nodes is attached to the casing string by one or more clamps; and

each of the one or more clamps comprises;

a first arcuate section;

a second arcuate section;

a hinge for pivotally connecting the first and second arcuate sections; and

a fastening mechanism for securing the first and second arcuate sections around an outer surface of the casing string.

26. A method of monitoring a parameter along an annular region in a cased-hole, subsea wellbore, the wellbore having a wellhead placed proximate a bottom of a body of water, and the method comprising:

running joints of casing into the wellbore, the joints of casing being connected by threaded couplings to form a casing string;

attaching a series of subsurface communications nodes to the joints of casing according to a pre-designated spacing, wherein adjacent subsurface communications nodes communicate by acoustic signals transmitted through the joints of casing;

providing one or more sensors along the wellbore, each sensor being configured to sense the parameter within the annular region, and each sensor being in electrical communication with an associated subsurface communications node using electrical signals;

placing a cement sheath within the annular region formed between the casing string and a surrounding subsurface matrix at least partially along the casing string;

attaching a topside communications node to the wellhead, wherein the topside communications node comprises an electro-acoustic transducer for receiving the acoustic signals from the subsurface communications nodes;

sending acoustic signals from the one or more sensors to a receiver at the surface via the series of subsurface communications nodes and the topside communications node, with each acoustic signal including a packet of information that comprises an identifier for the subsurface communications node that originally transmitted the acoustic signal transmitted through the joints of casing, and an acoustic waveform having an amplitude indicative of the parameter;

analyzing at least one of the electrical signals and the acoustic signals from adjacent pairs of the subsurface communications nodes to monitor the parameter; and

evaluating the integrity of the cement sheath, wherein evaluating the integrity of the cement sheath comprises measuring attenuation of the acoustic signals between pairs of subsurface communications nodes.

27. The method of claim 26, wherein the body of water is an ocean, a sea, a bay or a lake.

28. The method of claim 27, wherein each of the subsurface communications nodes comprises:

a sealed housing;

an electro-acoustic transducer and associated transceiver residing within the housing configured to relay acoustic signals, with each acoustic signal including a packet of information that comprises an identifier for the subsurface communications node originally transmitting the signal, and an acoustic waveform; and

an independent power source also residing within the housing for providing power to the transceiver.

29. The method of claim 28, wherein the housing for each of the subsurface communications nodes is fabricated from a steel material, with the steel material of the housing having a resonance frequency compatible within a bandwidth of a resonance frequency of the acoustic waveforms transmitted through the joints of casing.

30. The method of claim 26, wherein:

the parameter is acoustic values of the waveforms; and

the step of analyzing the acoustic signals further comprises;

identifying amplitude values generated by each of the subsurface communications nodes; and

comparing those amplitude values to a baseline amplitude value.

31. The method of claim 26, further comprising producing hydrocarbons through the wellbore.

32. The method of claim 30, further comprising:

identifying a subsurface communications node sending acoustic signals indicative of poor cement integrity within the surrounding cement sheath.

33. The method of claim 32, further comprising:

perforating the joint of casing supporting the subsurface communications node sending the acoustic signals indicative of poor cement integrity within the surrounding cement sheath; and

squeezing cement through the perforated joint of casing and into the annular region around the casing string.

34. The method of claim 32, wherein evaluating the integrity of the cement sheath further comprises comparing the attenuation of the acoustic signals with cement bond-log data.

35. The method of claim 26, wherein:

the parameter is pressure;

each of the sensors comprises a pressure sensor; and

the step of analyzing the acoustic signals comprises reviewing pressure data generated by the pressure sensors.

36. The method of claim 35, further comprising:

determining that a condition of excess pressure exists within the annular region; and

sending an actuation signal from the surface, through the topside communications node, and through the subsurface communications nodes, node-to-node, to a sliding sleeve to open the sliding sleeve, thereby relieving annular pressure behind the casing string.

37. The method of claim 26, wherein:

the parameter is casing strain;

one or more of the sensors comprises a strain gauge;

electro-acoustic transceivers transmit acoustic signals up the wellbore representative of strain readings from the strain gauge, node-to-node, as part of the packets of information; and

the step of analyzing the acoustic signals comprises reviewing strain data generated by the strain gauges.

38. The method of claim 26, wherein:

the parameter is temperature;

one or more of the sensors comprises a temperature sensor; and

electro-acoustic transceivers transmit acoustic signals up the wellbore representative of temperature readings from the temperature sensor, node-to-node, as part of the packets of information.

39. The method of claim 38, wherein the step of analyzing the acoustic signals further comprises:

identifying temperature values generated by the sensors to determine the presence or absence of cement in the annular region through monitoring a heat-of-hydration of the cement as it sets.

40. The method of claim 26, further comprising:

determining that a condition of excess pressure exists within the annular region; and

perforating the casing string in order to relieve annular pressure behind the casing string.

41. The method of claim 26, further comprising:

providing a sliding sleeve along the casing string, wherein the sliding sleeve is configured to open in response to an actuation signal, thereby relieving annular pressure behind the casing string.

42. The method of claim 41, wherein:

the sliding sleeve comprises a strain gauge or a pressure sensor; and

the actuation signal is an electrical actuation signal received from the associated strain gauge or pressure sensor that causes the sliding sleeve to open where a strain gauge reading, a pressure reading, or both, are indicative of a trapped annulus.

43. The electro-acoustic telemetry system of claim 42, wherein:

the sliding sleeve comprises a processor that compares strain gauge and pressure data with pre-determined baseline values, and sends the actuation signal if the value of the strain gauge data, the pressure data, or both exceeds the pre-determined baseline values, causing the sliding sleeve to open automatically; and

the step of analyzing the at least one of the electrical signals and the acoustic signals is conducted by the processor in the sliding sleeve.

44. The method of claim 26, wherein a frequency band for the acoustic wave transmission by the transceivers is 25 KHz wide.

45. The method of claim 26, wherein a frequency band for the acoustic wave transmission by the transceivers operates from 50 kHz to 500 kHz.

46. The method of claim 26, wherein acoustic signals provide data that is modulated by (i) a multiple frequency shift keying method, (ii) a frequency shift keying method, (iii) a multi-frequency signaling method, (iv) a phase shift keying method, (v) a pulse position modulation method, or (vi) an on-off keying method.