Real-Time Well Surveillance Using a Wireless Network and an In-Wellbore Tool

• US 20160215612A1
• Filed: 10/23/2015
• Published: 07/28/2016
• Est. Priority Date: 01/26/2015
• Status: Active Grant

• Current Assignee: Timothy I. Morrow
• Original Assignee: Timothy I. Morrow
• Inventors: Morrow, Timothy I.
• Granted Patent: US 10,408,047 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: E21B 47/01 Devices for supporting measuring instruments on drill bits, pipes, rods or wirelines; Protecting measuring instruments in boreholes against heat, shock, pressure or the like
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves

Abstract

A method of transmitting data in a wellbore uses a signal receiver that is run into the wellbore on a working string. The signal receiver receives wireless signals from receiver communications nodes placed along the wellbore. The data from those signals is then sent up the wellbore, either by directing the signals directly up the working string, or by spooling the string to the surface and uploading the data. Sensors and associated communications nodes arc placed within the wellbore to collect data. The communications nodes may be the signal receiver nodes; alternatively, the communications nodes may send data from the sensors up the wellbore through acoustic signals to a receiver communications node. In the latter instance, intermediate communications nodes having electro-acoustic transducers are used as part of a novel telemetry system.

Claims

1. A method of transmitting data along a wellbore up to a surface, comprising:

placing two or more downhole sensors along the wellbore proximate a depth of a subsurface formation, the subsurface formation containing hydrocarbon fluids;

generating signals at the downhole sensors that are indicative of one or more subsurface conditions;

providing two or more sensor communications nodes along the wellbore proximate a depth of a subsurface formation, each sensor communications node having a transceiver for transmitting data corresponding to the generated signals as data signals;

running a downhole tool into a wellbore using a working string, the downhole tool having an associated signal receiver;

transmitting data signals from the sensor communications nodes to the signal receiver by means of a wireless transmission as the signal receiver moves within a designated proximity to the respective sensor communications nodes within the wellbore; and

receiving data from the signal receiver at the surface.

2. The method of claim 1, wherein the surface is an earth surface, or a water surface.

3. The method of claim 1, wherein each sensor communications node is secured to a joint of production casing, to a base pipe of a sand screen, or to a sliding sleeve device.

4. The method of claim 1, wherein:

the sensors are (i) pressure sensors (ii) temperature sensors, (iii) induction logs, (iv) gamma ray logs, (v) formation density sensors, (vi) sonic velocity sensors, (vii) vibration sensors, (viii) resistivity sensors, (ix) flow meters, (x) microphones, (xi) geophones, (xii) strain gauges, or (viii) combinations thereof.

5. The method of claim 4, wherein:

the working string is a slick line, an electric line, a string of coiled tubing, or a jointed working string; and

the wireless transmission of data signals is by radio waves, inductive electro-magnetic waves, ZigBee, Wi-Fi, or optic waves.

6. The method of claim 4, wherein the designated proximity is between 0.1 and 25 feet (0.03 and 7.6 meters).

7. The method of claim 6, wherein the wireless transmission occurs as the e downhole tool crosses a respective sensor communications node in the wellbore.

8. The method of claim 6, wherein:

the working string is an electric line;

the downhole tool is a perforating gun that is run into the wellbore on the electric line;

transmitting data signals from the sensor communications nodes to the signal receiver comprises transmitting data signals in connection with a zone being perforated; and

receiving data from the signal receiver at the surface comprises receiving data through the electric line in real time.

9. The method of claim 6, wherein:

the working string is coiled tubing;

the downhole tool is a nozzle at an end of the coiled tubing;

transmitting data signals from the sensor communications nodes to the signal receiver comprises transmitting data signals in connection with a zone receiving an injection of a fracturing fluid or an acid; and

receiving data from the signal receiver at the surface comprises spooling the coiled tubing to the surface retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

10. The method of claim 6, wherein:

the downhole tool is a logging tool that is run o the wellbore on a line; and

transmitting data signals from the sensor communications nodes to the signal receiver comprises transmitting data signals in connection with a well logging operation.

11. The method of claim 10, wherein:

the working string is an electric line; and

receiving data from the signal receiver at e surface comprises receiving data through electric line in real time.

12. The method of claim 10, wherein:

the working string is a slick line or coiled tubing; and

receiving data from the signal receiver at the surface comprises spooling the working string to the surface, retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

13. The method of claim 6, wherein:

the working string is jointed pipe or coiled tubing;

the downhole tool is a full bore drift tool;

transmitting data signals from the sensor communications nodes to the signal receiver comprises transmitting data signals indicative of drift; and

receiving data from the signal receiver at the surface comprises raising the working string to the surface, retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

14. The method of claim 1, wherein:

the wellbore has a horizontal portion extending along the subsurface formation;

the horizontal portion is divided into production zones; and

a downhole sensor and corresponding sensor communications node are placed within each production zone.

15. The method of claim 1, further comprising:

beginning production operations;

running a battery recharging device into the wellbore, the batter recharging device emitting a signal to recharge a battery; and

approaching each sensor communications node with the battery recharging device such that the sensor communications nodes each receive the recharging signal.

45. The acoustic telemetry system of claim 12, wherein each sensor communications node transmits processed signals to a first of the corresponding intermediate communications node (i) by means of an insulated wire, or (ii) by electro-acoustic waves using the subsurface pipe as an acoustic carrier medium.

16. A method of transmitting data along a wellbore up to a surface, comprising:

placing two or more downhole sensors along the wellbore proximate a depth of a subsurface formation, the subsurface formation containing hydrocarbon fluids;

generating signals at the downhole sensors that are indicative of one or more subsurface conditions;

providing two or more sensor communications nodes along the wellbore proximate respective zones of a subsurface formation where hydrocarbon fluids are to be produced, each sensor communications node being configured to process signals generated by a downhole sensor, and transmit those signals up the wellbore;

providing two or more intermediate communications nodes along the wellbore, each intermediate communications node being configured to receive signals from a sensor communications node, and transmit the signals, node-to-node, up to a receiver communications node as electro-acoustic waves using subsurface pipe as a carrier medium, with the receiver communications node having a transceiver for transmitting data corresponding to the electro-acoustic waves as data signals;

running a downhole tool into a wellbore using a working string, the downhole tool having an associated signal receiver;

transmitting data signals from the receiver communications nodes to the signal receiver by means of a wireless transmission as the downhole tool moves within a designated proximity to a respective receiver communications node in the wellbore; and

receiving data from the signal receiver at the surface.

17. The method of claim 16, wherein a sensor communications node transmits processed signals to a corresponding intermediate communications node (i) by means of an insulated wire, or by electro-acoustic waves using the subsurface pipe as an acoustic carrier medium.

18. The method of claim 16, wherein the intermediate communications nodes reside proximate respective zones of a subsurface formation where hydrocarbon fluids are not to be produced.

19. The method of claim 16, wherein:

the surface is an earth surface, or a water surface; and

the method further comprises;

beginning production operations;

running a battery recharging device into the wellbore, the battery recharging device emitting a signal to recharge a battery; and

approaching each sensor communications node with the battery recharging device such that the sensor communications nodes each receive the recharging signal.

20. The method of claim 16, wherein:

each sensor communications node is secured to a joint of production casing, to a base pipe of a sand screen, or to a sliding sleeve device; and

the subsurface pipe comprises joints of production casing, base pipe of sand screen joints, a sliding sleeve device, or combinations thereof.

21. The method of claim 16, wherein:

the sensors are (i) pressure sensors, (ii) temperature sensors, (iii) induction logs, (iv) gamma ray logs, (v) formation density sensors, (vi) sonic velocity sensors, (vii) vibration sensors, (viii) resistivity sensors, (ix) flow meters, (x) microphones, (xi) geophones, (xii) strain gauges, or (xiii) combinations thereof.

22. The method of claim 21, wherein:

the working string is a slick line, an electric line, a string of coiled tubing, or a workover drill string; and

the wireless transmission of data signals to the signal receiver is by radio waves, inductive electro-magnetic waves, ZigBee, or optic waves.

23. The method of claim 21, in the designated proximity is between 0.1 and 25 feet (0.03 and 7.6 meters).

24. The method of claim 23, wherein the wireless transmission occurs as the downhole tool crosses a respective sensor communications node in the wellbore.

25. The method of claim 21, wherein:

the working string is an electric line;

the downhole tool is a perforating gun that is run into the wellbore on the electric line;

transmitting data signals from the receiver communications nodes to the signal receiver comprises transmitting data signals in connection with a zone being perforated; and

receiving data from the signal receiver at the surface comprises receiving data through the electric line in real time.

26. The method of claim 21, wherein:

the working string is coiled tubing;

the downhole tool is a nozzle at an end of the coiled tubing;

transmitting data signals from the receiver communications nodes to the signal receiver comprises transmitting data signals in connection with a zone receiving an injection of a fracturing fluid or an acid; and

receiving data from the signal receiver at the surface comprises spooling the coiled tubing to the surface, retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

27. The method of claim 21, wherein:

the downhole tool is a logging tool that is run to the wellbore on a line; and

transmitting data signals from the receiver communications nodes to the signal receiver comprises transmitting data signals in connection with a well logging operation.

28. The method of claim 27, wherein:

the working string is an electric line; and

receiving data from the signal receiver at the surface comprises receiving data through the electric line in real time.

29. The method of claim 27, wherein:

the working string is a slick line or coiled tubing; and

receiving data from the signal receiver at the surface comprises spooling the working string to the surface, retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

30. The method of claim 21, wherein:

the working string is jointed pipe or coiled tubing;

the downhole tool is a full bore drift tool;

transmitting data signals from the receiver communications nodes to the signal receiver comprises transmitting data signals indicative of drill; and

receiving data from the signal receiver at the surface comprises raising the working line to the surface, retrieving the signal receiver, and uploading data from the signal receiver to a micro-processor.

31. The method of claim 21, wherein each of the intermediate communications nodes comprises:

a housing having a sealed bore, with the housing being fabricated from a material having a resonance frequency;

an electro-acoustic transducer and associated transceiver residing with bore for transmitting signals from the sensor as acoustic signals; and

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

32. The method of claim 31, therein each of the two or more downhole sensors resides within the housing of a corresponding sensor communications node.

33. The method of claim 31, wherein each of the two or more downhole sensors resides adjacent the housing of a corresponding sensor communications node, and is in electrical communication with the corresponding electro-acoustic transducer.

34. The method of claim 32, wherein:

each of the intermediate communications nodes further comprises at least one clamp for radially attaching the node onto an outer surface of a subsurface pipe;

the subsurface pipe represents a joint of casing, a joint of liner, a fracturing sleeve, or a base pipe of a joint of sand screen; and

the step of providing two or more intermediate communications nodes along the wellbore comprises clamping the communications nodes to an outer surface of the subsurface pipe.

35. The method of claim 34, wherein the at least one clamp 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 subsurface pipe.

36. The method of claim 21, wherein:

wellbore comprises a plurality of fracturing sleeves placed along designated zones; and

each fracturing sleeve comprises an associated downhole sensor and associated sensor communications node.

37. The method of claim 16, further comprising:

processing data signals received by the receiver signal at the surface for analysis of the one or more subsurface conditions.

38. The method of claim 37, wherein:

the transceivers in the intermediate communications nodes receive acoustic waves at a first frequency, and re-transmit the acoustic waves to a next intermediate communications node at a second different frequency; and

the transceivers listen for the acoustic waves generated at the first frequency for a longer time than the time for which the acoustic waves were generated at the first frequency by a previous communications node.

39. The method of claim 37, wherein:

the two or more intermediate communications nodes represent discreet series of acoustic communications nodes;

each series of acoustic communications nodes comprises at least three acoustic communications nodes; and

the acoustic communications nodes are spaced apart at one node per joint of pipe.

40. The method of claim 16, wherein:

the wellbore has a horizontal portion extending along the subsurface formation;

the horizontal portion is divided into production zones; and

a downhole sensor and corresponding sensor communications node are placed with each production zone.

41. A downhole acoustic telemetry system, comprising:

two or more downhole sensors residing along a wellbore proximate a depth of a subsurface formation, with each of the downhole sensors being configured to sense a subsurface condition and then send a signal indicative of that subsurface condition, and with each of the sensors residing along a designated production zone within a horizontal portion of the wellbore;

two or more sensor communications nodes also residing along the wellbore proximate a depth of the subsurface formation, wherein each of the sensor communications nodes comprises;

a housing having a sealed bore, with the housing being fabricated from a material having a resonance frequency;

an electro-acoustic transducer and associated transceiver residing within the bore for transmitting signals from the sensor as acoustic signals, and

an independent power source residing within the bore providing power to the transceiver;

a series of intermediate communications nodes placed between the two or more sensor communications nodes, each intermediate communications node comprising;

a housing having a sealed bore, with the housing being fabricated from a material having a resonance frequency;

an electro-acoustic transducer and associated transceiver residing within the bore for transmitting acoustic signals along a subsurface pipe, node-to-node, and

an independent power source residing within the bore providing power to the transceiver;

a receiver communications node along the series of intermediate communications nodes, the receiver communications node having a transceiver for wirelessly transmitting data corresponding to the electro-acoustic waves to a downhole signal receiver as data signals.

42. The acoustic telemetry system of claim 41, wherein the sensors are (i) pressure sensors, (ii) temperature sensors, (iii) induction logs, (iv) gamma ray logs, (v) formation density sensors, (vi) sonic velocity sensors, (vii) vibration sensors, (viii) resistivity sensors, (ix) flow meters, (x) microphones, (xi) geophones, (xii) strain gauges, or (xiii) combinations thereof.

43. The acoustic telemetry system of claim 42, wherein each of the two or more downhole sensors resides within the housing of a corresponding sensor communications node.

44. The acoustic telemetry system of claim 42, wherein each of the two or more downhole sensors resides adjacent the housing of a corresponding sensor communications node, and is in electrical communication with the corresponding electro--acoustic transducer.

46. The acoustic telemetry system of claim 42, wherein a frequency band for the acoustic wave transmission by the transceivers operates from 50 kHz to 500 kHz.