CA2259176C - Method and apparatus for testing, completing and/or maintaining wellbores using a sensor device - Google Patents

Abstract

The present invention is an improved method and apparatus for testing and monitoring wellbore operations. The invention is (1) a data acquisition device capable of monitoring, recording wellbore and/or reservoir characteristics while capable of fluid flow control;
and (2) a method of monitoring and/or recording at least one downhole characteristic during testing, completion and/or maintenance of a wellbore. The invention includes an assembly within a casing string comprising a sensor probe having an optional flow port allowing fluid flow while sensing wellbore and/or reservoir characteristics. It also includes a microprocessor, a transmitting device, and a controlling device located in the casing string for processing and transmitting real time data. A memory device is also provided for recording data relating to the monitored wellbore or reservoir characteristics. Examples of downhole characteristics which may be monitored include:
temperature, pressure, fluid flow rate and type, formation resistivity, cross-well and acoustic sesmometry, perforation depth, fluid characteristic or logging data. With the microprocessor, hydrocarbon production performance may be enhanced by activating local operations in additional associated downhole equipment, e.g., water shut-off operations at a particular zone, maintaining desired performance of a well by controlling flow in multiple wellbores, zone mapping on a cumulative basis, flow control operations, spacing casing and its associated flow ports in multiple zone wellbores, maintaining wellbore and/or reservoir pressure, sensing perforation characteristics, sensing reservoir characteristics or any number of other operations.

Description

MFTHpl3 & APPARATUS FOR TEST, 'due. GOME~LETING AMiDIOR MAfNTAINiNG
WELLBDRES ltSiNG A SENSOR DEVICE
BACKGROUND OF THE INVFN ON
This invention relates to a method of testing, completing and maintaining a hydnacarbon wellbore. More particularly, but not by way of limitation, this invention relates to a method and apparatus far pfacirtg within a wellbone, a flow contr~pl device containing a sensor for monitoring., tesffng a weflbor~e andlor controlling the flow of hydrocarbons from a reservoir.
The production far ail and gas reserves has taken the industry to remote sites including inland and offshore locations. Histarioally, the cost for developing and maintaining hydnxarizon production has been very (high, and as the prnductlan for hydrocarbons continues to occx~r in these remote and deep water areas, costs stave escalated because of the amount of equipment, personnel and logistics required in these areas.
Production wells wiu often encounter seven~i hydrocarbon zones within a reservoir and multiple wellbores must be utilized to exploit and recover the hydrocarbon reserves. During the pracluctive life aif these welts, the well must' be tested and information retrieved oonceming tree wellbore andlor reservoir 2o characteristics including hydrocarbon analysis so that hydrocarbon production and retrieval Is psfiomted in the most effiaent manner and at maximum capacity.
Well ..._ . h~.... -.~~..~:: . ........

operators desire maximum recovery from productive zones, and in order to maximize production, proper testing, completion and control of the well is required.
Many hydrocarbon reservoirs by their nature comprise consolidated or unconsolidated rock and/or sandstone, water, oil, gas or consolidate. Thus, these formations may produce sand particles and other debris that can cause erosion and other problems in the wellbore and at the surface facility, as well as water, gas, etc.
which generally affect the productivity of the well. Therefore, various devices for preventing and/or monitoring production from the reservoir into the wellbore have been developed in the past.
1 o One common method is to place instruments on the surface such as production platforms and run sensors into the welibore through a wireline or coil tubing methods. The data collected through these wireline and surface sensors are used to ascertain the performance of a wellbore within a particular reservoir area.
These information retrieval methods and subsequent assessment of such information is well known in the industry and to those of ordinary skill in the art and the clear disadvantages are also apparent.
These current techniques for wellbore and reservoir data collection include time consuming procedures of positioning a wireline or coil tubing rig or unit on a surtace vehicle or platform to suspend a sensor or a set of sensors and taking

2 o readings. Subsequently, the sensors are withdrawn and data analyzed.
During all the performance of these operations, hydrocarbon production is interrupted because of safety, environmental and/or rig-up issues. It is clear to those in the industry that enormous costs are involved in not only delaying production but also having to incur costs for simply obtaining the wellbore or reservoir information from the wellbore.

An illustrative list of the disadvantages from the above procedure follows.
First, production is lost for a certain time period while on-going rig or platform costs remain. This shut-off in hydrocarbon production has considerable impact on many high volume operators affecting profitability of the well. Additionally, the risks of wellbore damage clearly exist due to the possibility of lost tools and equipment in the wellbore. Again, in such circumstances, hydrocarbon production is lost and additional costs are incurred in restoring the wellbore by removing the lost equipment through additional services. Second, the equipment and logistics relating to wireline and coiling tubing operations in many deep water and remote areas make 1o this type of data gathering procedure a costly exercise since the formation is exposed to damaging drilling andlor completion fluids. Third, the well data is only gathered when a problem is noticed in hydrocarbon production performance and corrective action is necessary. This type of well maintenance is clearly inferior to having a continuous monitoring system that anticipates and avoids a problem.
Therefore, there is a need for a method and apparatus for testing, completing and maintaining a well that minimizes time spent in testing hydrocarbon production and reservoir characteristics in the wellbore. Further, there is a need for a method and apparatus that minimizes formation damage while maximizing productivity of the well. Also, there is a need for methods and apparatus for testing of exploratory wells 2 a through existing wells that are faster and more economical than present methods.
SUMMARY OF THE INVENTION
The present invention is directed to an improved method and apparatus for testing, completing and monitoring a wellbore construction. The invention may be alternatively characterized as either (1 ) a data acquisition device capable of

3

4 PCT/US97/10893 monitoring, recording wellbore and/or reservoir characteristics and including control of hydrocarbon production flow through a sensor device; or (2} a method of monitoring and/or recording at least one downhole characteristic during testing, completion, and/or maintenance of a wellbore.
When characterized as a data acquisition device, the present invention includes an assembly within a casing string comprising a sensor device or probe including an optional flow port allowing flow of hydrocarbons while having sand controlling ability. The present invention includes (1 ) at least one sensor device for sensing welibore and/or reservoir characteristic, (2) a transmitting and controlling io device located and carried in the casing string for transmitting data as the well is being tested, completed and/or maintained, and (3) an optional memory device located and carried in the sensor device and/or casing string for recording data pertaining to the monitored wellbore and/or reservoir characteristic including an information retrieving tool. The present invention has the capability of continuing to collect information and characterization of the wellbore and/or formation even when hydrocarbon flow is terminated or restricted by the sensor device.
The present invention comprises a data acquisition device containing a sensor linked to and/or containing a microprocessor device, and/or a recording device for retrieving at least one predefined wellbore or reservoir parameter or 2 o characteristic during wellbore testing, completion and/or production phases.
Examples of downhofe characteristics which may be monitored include:
temperature, pressure, fluid flow rate and type, formation resistivity, cross-welt and acoustic sesmometry, perforation depth, fluid characteristic or logging data. Further, with the addition of the microprocessor to the sensor device, the hydrocarbon production . _..._.~. ._...

pertormance is enhanced by any number of downhole operations by activating localized operations in additional associated equipment, e.g., water shut-off operations at a particular zone, maintaining desired performance of a well by controlling flow in multiple wellbores, zone mapping on a cumulative basis, flow control operations, spacing casing and its associated flow ports in multiple zone wellbores, maintaining wellbore and/or reservoir pressure, sensing pertoration characteristics, sensing reservoir characteristics or any number of other operations.
The present invention also includes the use of an optional permeable core or port located about the sensor device. The permeable core or filter media allows flow of hydrocarbons while preventing the flow of sand and other particulate matter. The permeable core comprises one or more of the following elements: brazed metal, sintered metal, rigid open cell foam, resin coated sand or a porous hydrophilic membrane.
Another related feature of the invention includes the use of a soluble i5 compound surrounding the filter media which may be dissolved and/or removed at the option of the wellbore operator so that the filter media may be selectively opened to allow flow. Still another feature includes using a hydrophilic membrane in the sensor device that allows the flow of hydrocarbons, but not in-situ water.
Another feature of the invention is the use of a plurality of sensor devices in 2 o multiple zone wellbores allowing productive intervals to be selectively opened during remedial wellbore workover by dissolving a soluble compound coating the filter media or opening a valve or choke. Another feature of the invention includes the ability of extending the sensor device from a retracted position to an expanded position as desired by the wellbore operator.

5 Another feature of the invention is that of having the sensor device being positioned only on the outer diameter of the casing, rather than having it initially refiacted in the casing and then extenders outwardly. Ar~otherfeature includes shaping the extendible tubular member so as to be embed into the formation as it is being extending. Ail of these features ane described in detail in U.S. Patent No.
5,829,52tit.
An improved method for weubore testing, completion and rrtair~tenance is also disclosed herein. The er~ethod comprises positioning a casing string into a wellbore having a sensor device in communicra~tion wifh a target reservoir. The method lnciudes correlating the position of the sensor device with the target reservoir so that the '10 sensor device is adjacent the target reservoir. Then the sensor device is activated to test, complete andlar maintain a welibore. The activation is accomplished through arty number of methods discussed in U.S_ Patent No. 5,828,520.
The improved method further Comprises using the sensor linked to a microprocessor contained in the Sensor device to evaluate, monitor, record andlor 95 control any number of downhvle operations previously described herein during either weliiaore testing, Completion or production phases. VNhen using a memoryr device downhole, the stored data information may be retrieved by any number of methods.
For instance, data may lee retrieved when a well is being worked over. At this time, the welt is easily acrxssibie and therefore data retrieval equipment may be deployed to ~0 retrieve the data informa#or! from the memory device. Aitemateiy, a information from the surface may be sent downhoie and stored in the memory device. Such information may relate to comparative data or control operations.
Information stored in the memory device is normally more useful if it is capable of being retrieved during periods when the wellbore is in operation.
During these periods, the invention is equally accessible for data retrieval through a data retrieval mandrel. The data retrieval mandrel may be deployed downhole through the production tubing to retrieve the stored data information on the wellbore and/or fluid characteristics. The mandrel is designed to be aligned with the sensor devices and the attendant memory device. Once aligned, information may be transferred 1 o selectively as needed.
A method of testing an exploratory well to a target reservoir is also disclosed.
The method comprises positioning a casing string in an existing well or an exploratory well and wherein the casing string contains sensing device to monitor any number of downhole operations during the exploratory phases of wellbore construction. The position of the sensor device is correlated so that the sensor device is adjacent the target reservoir and activating the sensor device provides data from the sensor which is in communication with the target reservoir. Testing the wellbore with the sensor includes monitoring any number of reservoir characteristics pertaining to a hydrocarbon zone and, if necessary, even allowing flow from the 2 0 target reservoir.
In one wellbore embodiment, the method may be accomplished numerous times as described herewith. In such an embodiment, the exploratory well contains a lower, an intermediate, and an upper target reservoir. The method comprises positioning a casing string with possibly several sensor devices so that they correspond to depths of the lower; intermediate and upper target reservoirs.
The testing of the wellbore containing the various hydrocarbon zones includes lowering a casing string with a retrievable isolation packer for isolating the wellbore at a required zone; setting the isolation packer at a position above the lower target s reservoir but below the intermediate target reservoir; and testing for any downhole characteristic of the lower target reservoir, including allowing flow from the formation, if necessary.
The method may further comprise shutting-in the well using data obtained through the sensor by placing a bridge plug in the well at a point above the lower to target reservoir; repositioning the isolation packer to a point above the intermediate reservoir; then, setting the isolation packer, and testing and flowing the well, from the intermediate reservoir and so forth with any number of target zones or reservoirs.
A substantial advantage of the present invention includes obtaining data rapidly thereby greatly improving the efficiency and accuracy of wellbore testing i5 and/or maintenance. Depending on the configuration of the sensor device, real time data is available to the well operator during exploratory testing, during completion and during production of a wellbore. It is clear to those skilled in the art as to the value of such information as it allows for substantial savings in wellbore trips, operations, and safety. Another advantage includes being able to test an 2 o exploratory well by custom designing the casing string after reviewing downhole logs which provide the position of the hydrocarbon zones, and thereafter testing the zones individually.
Another significant advantage of the present invention allows for minimizing the time for wellbore completion because of the data available through the sensor ....... ~.... . _........ . ...... . .... .. ... . T . ...

device. When completion operations are rnonitared, it is likely that the wellbore will operate to full capacity and enhanced recovery of hydmcarfyan from the reservoir due to data verification of wentaore as it is being Completed, Further, significantly less time is expended completing a weltbore oonstn.~ction with ;such data and therefore having 8 the additional advantage that formation damage is prevented due to drilling and completion fluids stagnating in the wellbore.
Another advantage includes providing sut>stantiat cost savings by using Less completion equipment.
Another advantage includes use of a filter media comprising a metal core which is highly porous, permeable, anti that which has very high compressive strength values ensuring that the sensor will retain its integrity during any numtrer of operations.
Similarly, it becom~s dear the many significant advantages obtained from having a sensor in close proximity to the target zone in maintaining welbore i5 productiari_ "the close proximity allows for immediate and critical data useful in maintaining maximum production from a wellbon::. ~imilariy, recorded data may be very useful during workover operations giving the well: operstar detailed history of the wellbore Condition during production.
Accordingly, in one aspect of the present inven~tia~n there is provided a device 24 for monitoring a reservoir in a welibore, said we9bore having at fe2st one target formation and having a tubular member comprising caning or production tubing, said device for monitoring further comprising;
at least one sensor comprising an infomtation retrieval device, being mounted on the tubular member on a probe such that said sensor is retained subs#antially 25 within said tubular member until ii is positioned adjacent the target formation whereupon said probe is extendable with s8ici sensor to position said sensor adjacent the target formation far gathering wellbore characteristic data therefrom.

According to another aspect of the present invention there is provided a device for monitoring a reservoir in a weilbare comprising:
a tubular member being received in the wel(bore adjacent a target formation;
one or more screen liners mounted along the tubular member, at least one sensor, comprising 3n information retrievat device, being mounted on the tubular member and positioned at predetermined intervals along the length of the tubular member;
at least one sensor, each comprising an information retrieval device, being mounted on the screen liner and positioned at predetemtined intervals along the 14 length of the liner; arid the tubular member being positioned in the weAbore to extend adj8cent the target formation for gathering wel(bore characteristic data therefrom.
According to yet another aspect of the present invention there is provided an apparatus, for perForming one of wellbore testing, completion and production, which i5 in communicatvn with a target reservoir in a wellbore Jomprising:
a tubular pipe having an aperture for communit~tmg with the target reservoir;
and at least one flow control device moveably mounted within the aperture of the tabular pipe far receiving fluid flow from the wellbore ovmprising:
26 a tubular member moveatxly mounted on the tubular pipe for movement in a direction generally along the tubular member's longitudinal axis between a retracted position primarily within the tubuhar pipe and an extended position towards a sidewall of the welltrore near the target reservoir and, a sensor device located in the tubular member for selectively monitoring a wellt~ore parameter.
9a . ,... ~~.r.;.; ~ ~,..,~." ~,".w,. ~. h. w,. ø..~.._.~..~,F» F ~,.._~r. " ....
.. _....._,. _..._.... _ According to stilt yet another aspect of the present invention there is provided a method of wellbore completiqn, including a method for monitoring a wellbore parameter during hydrocarbon production, comprising:
positioning a tubular into a wellbore, having a sensor device movably mounted 5 for receiving a wellbore parameter signal and having fli.rid communication witfi a Target reservoir;
correlating trie position of the sensor device with the target reservoir so that the sensor device is adjacent the target reservoir, extending the sensor device toward the target reservoir tram a retracted 10 position to an extended position;
sensing a uvellbore pararn eter signal from the s3ubterranean formation by way of the sensor device;
transmitting the wellbore parameter signal front the sensor device to a microprocessor;
1 ~ processing the weltboee parameter signal with the microprocessor; and transmitting a control signet from the microprocessor to a control device located downhole for carrying out a command instruction.
According to still yet another aspect of the present invention there is provided a method of testing an exploratory well leading to a target reservoir, comprising:
20 positioning in the exploratory wellbare a tubular having at least one flow control device for receiving selective fluid comrnunication from an adjacent target nesenrair, the flow control device Comprising:
an extendible member, containing a filter media avowing selective fluid flow, extendible from within the tubular in a retracted position to an expanded position z5 toward the wellbore watt;
a sensor device located within the extendible member for receiving wellbare parameter signals:
9b correlating the position of the flow control device so float it is adjacent the target reservoir, activating the flow contras device so that the extendible member moves toward the wellbore wall;
5 testing the hydrocarban zone by flowing the target reservoir through the filter media into the tubular;
receivsng a weltbote param$ter signs! using sand sensor device;
ttanssnitting the welibore parameter signal to a microprocessor and processing the signal; and 10 sending a control instruction to a control devicr~ located within the wellbore far perfom~ring a control operation.
According to stilt yet another aspect of the present invention there is provided a device for monitoeing a reservoir in a wellbaris, said weUbore having at least one target formation and having a tubular memt~er compri.~ir~g casing or production tubing, 15 said device for monitoring further comprising:
at least one sensor comprising an information retrieval device, being mounted on the tubular member and positioned an the tubular member adaacent the target formation for gathering wellbore characteristic data therefrom;
at lesast one extendible probe rncunted an the tubular member having a 2o sensor, said probe extended toward the sidewa;l of the wellbore when it is in a iuUy extended poSiti~on; and said probe receives fluid flow from an adjacent fannation.
According to still yet another aspect of the present invention there is provided a device for monitoring a reservoir in a wellbore, said wellbore having at least one 25 target formation and having a tubul2~r member comprising casing or production tubing, said device for monitoring further cvmprising_ gc at feast one sensor comprising an infom~afion retrieval d~vice, being mounted on the tubular member and positioned an the tubular member adjacent the target formafion far gathering wellbore charaateri$tic data therefrom;
at least one housing defining a flow passage into the tubular member for 5 receiving fluid flaw from the reservoir and wherein said housing contains a filter media for retention of at least some of the particulate matter; and wherein said housing has a sensor in said housing for sensing fluid properties.
ACCOrding to still yet another aspect of the pre~ient invention there is provided a device for monitoring a reservoir in a wellbore, said uvellbore having at least one 1 o target formation arid having a tubular member comprising casing or produckion tubing, Sold deViCe for monitoring fut~ther comprising:
at least one sensor comprising an information retrieval device, being mounted on the tubular member and positioned on the tubular member adjacent the target fiormation for gathering wellbore characteristic data thr:refmm;
95 said sensor transmits a sensed wellbore char~icteristic data signal to a mtcroQrocessor at a surface location; and the microprocessor, after processing the received wettbore characteristic data signal, transmits a signal to implement a control instruction to a downhole control device.
8d According to still yet another aspect of the present invention there is provided a device for monitoring a reservoir in a wellbore, said v~reltbtsne having at least one target formation and having a tubular member comprising casing or production tubing, 5 said device for monitoring furki~er comprising:
at (east one sensor comprising an information mtrlevat device, being mounted on tyke tubular maml~er and positioned on the tubular member adjacent the target formation far gathering welfbore characteristic data thE:refrom; and a microprocessor mounted with said sensor fpr processing at least one data 9 o signal received from said sensor end for transmitting said signal to implement a control instruction to a dawnhole control device.
Addi~onal objects, features end advantages will become apparent in the detailed description which follows.
95 t3RtEF DESCRIPTION O>= THE DRA.WiNGS
FIGURE 't is an illustration of a drifting rig on or drilling platform having a wellbore section that intersects multiple subterranean reservoirs (partially shown), FIGURE 2 is a cross-sectional view of the exdandibte member with the sensor 9e WO 97149894 PCTlUS97/10893 device and microprocessor before engaging the wellbore wall.
FIGURE 3 is an electrical schematic of the sensor device connected to the microprocessor and downhole control systems.
FIGURE 4 is a cross-sectional view of the sensor device as seen in Fig. 2 s after being extended into contact with the formation.
FIGURE 5 is a cross-sectional view of a memory retrieval mandrel in alignment with the sensor devices and the memory devices in a well test string.
FIGURE 6 is a cross-sectional view of a well test string schematic shown testing a lower formation.
DETAILED DESCRIPTION OF THE INVENTION
1. Overview of wellbore testing, completion and production methods This invention relates to a method and an apparatus for testing exploratory wellbores, completion of wellbores and controlling production in a wellbore through z5 the use of an improved sensor device containing a sensor 136 (as seen in Figure 2).
In particular, in an embodiment of the present invention, an improved testing, monitoring and controlling sensor device 26 is described for testing, monitoring and controlling a wellbore zone from a remote location, as for example, a conventional semi-submersible drilling vessel 2 depicted in Figure 1 or such other surtace 2 0 location, or in the alternative from a downhole location 28 in a closed loop operation as will be apparent in the description provided herewith. A general description of the electronic sensing, communication and controlling system is provided herein while details will be incorporated in later pages.
Referring now to Fig. 1, a conventional semi-submersible drilling vessel 2 is _~__. _ _ T

depicted shonwirtg ~ drilling rig 4. 'Ehe wellbore using strings inducts the aorta~r, surface, artd irtt~etmed'sata strings 14, 16, arid 18, respe~livt~y. ~4s is well urxierstood by thane of orslirmry skiff in the art. ttte casing string int~.various subterranean reservoirs 22, some e~ which may s,~ntain hydra s. As is shown in fig. 1, ttte target reservoir ~4 has the production string 20 ~sitlc~ed ad,~acent thereto, in ar7 epen hole completior7 ~7_ tt si7ould tie clear to a perron skilled in the art that a weltbore oompletioh may include a casing string 9i3 extt~rlding to the target rese;v~oir ~4 along with the prGdtxtion string 2Q. In suds a wt::lnbore completion, the sensor devior3 may be locatetf on the casing string 18.
io The production string 2D eorrtains a plurality crf sensor devises 2fi fotl~l, rnor3itoring subterranean chatr3cteristics of mult~ie locatic~rr5. 9Ptionaity, the sensor devices 2E also c~trols reservoir sartc! production while attowing flow t~f ttydracart~rrs_ However, it should be clear that only a single sensor device 26 is r~cessa~ry for the present invention to function adequately. The sensor r3ev~ces 2G
15 are rnorxiter! within openings captained ~ the prcxlrtcticyn stung 20.w~1.
2. Corssfructi~nn c~f the sensor ~teylCe corttairtirtc~ a sensor Refie~ir~ to Fig. 2. an isometric vie'Mr of the prekerred ~rntsodiment is shown.
The sensor deYice 26 r.arnprises a housing .42, a fir'5t siecve 4~t and a second sleeve 46. The housing ~i2, on its outer diara>eter surface ~, is provided with an external zt~ thread 49 for mounting the ivonsir~g ~~ to the casing string 20 with .a matching thread 49. Mounting the sensor device 26 wsth a threaded ret~ethod will effectively seat the housing 42 tttneaded in the ~ening in trie wail of basing string ~0. It st~ruld be noted that any number of alternative means are evaiiabie for seaiingly mounting the housing 42 to a casing t5r production string. A groove 't3$,A in the housing 42 is 1 ~.

provided fdt' the ple~oement of a det>~ 139A fvr ~evetlting backward movement of the first sleeve ~4 is provided once it is extended outwardly. In the prefert~d embodiment, the detertt 13t3,A criss~es a snSp-ring operaGVely t8d W~h the first sleeve 44.
The first sleeve 4d ger~ratly comprises a tubular memt~- with a curved surface 70 at one end which cooperates with a wiper plug loci ~r~ sttoMrn) to a~nrate arid extend the first sleeve 44 outwardly tt~ward:c the weir wall. The f~
sleeve ~44 is moveably mounted within tsousirtg ~i2 with a seating member such as an .,~ng..1 ~0.
1 o The sectxad sleeve 46, which serves as the amtainer for the sensor 138 ~ l andtor nption~stfy inGkrdirrg a friter media 135, will now be c~stxibed. The seopr~d sleeve generally comprises a tubular member with an ouster surface haring a radial groc»ne for ptacement ref a sealing member SOB suds as an "(?-Ring" to s~lir~ly engage the first and second sleeves, 4d and 46. raspectively_ Ttie outer surface of the second sleeve AG also presents thereon a p'urality rat ratchet gnaaves 120 for o~rative association with a detest 13913 IaCated betvMeer~ the fast and seoor~d sleeves 44 and 46 respectively, thereby preventing t~ackw'ard mvrretnent of tt~
second sleeve 46. The second sleeve 4B has sufficient space 9D t~ insert a sensor 936, a mianprocessor 147 (not shown) ~ in the alternative, a rnerrrory devil ~(~,t 2 o shovvr~). Examples of sensor's rtow available induds Miniaturized Optimized Smart Sensors (iNOS~) available frwn Soutfwvest Research. institute m San Ihr>taniv, Texas. Along with the 141t7S$ techsrtoltsgy, high voltage power supplies used for detector bias voltages that generate potentials up to ~t kilowatts, weighing only 30 gratrts, and use only tat? milliwaits of power. In addition, modem set~scxs are now ......._ . ....._.. __..._~., t,.n.~~~,~F.~.$~~m,~~"~ ~~ ,"~ ~ ~,. . ....._ ..
..w.w.... _.

built to withstand higft temperai~ures and pressures, thus wail st~itt3d fvt downhale uuetlbore enviro~nm~tts.
When including a filter media 135 in the sensor device 26, to ~ikyw t,ydrnflow. a solutale disc 'i34 is motmted at the outer er~d of the secot7d sleeve 4& (tovsrards the weilhore wail 25), such that a per is forrr~ed far the ptac~merrt of a fitter media 135 coding a pormus cone. The core also contains a sensor 936 for sensing a welibare characteristic or tparameter. M ir~rmal ~p metrrber (not shown) ac a batTler coating may also be applied at trie opposite surface end of the filter media 1 ~ (towards the interic~ of the casing s-trittg ~0) to maintain ~.o tfire integrity of tire filter media 135 and the sensor 13h when hydraulic pressure is~~
applied from insir~e trie casing string 20. 1'he cap is designed to "pop nit"
at a pre-determined pressure level. trs the altemaiave, a barsiar rr~ateriaf may De canted along tt~e interior surface of the filter media 135 and whairh m;3y be dissolved ai a later time atlawing fluid cornmur~tion there thrraugt~.
~.5 It should be noted that the second sleeve a6 its provided with a chamfered sUrfaCe 133 contoured such that a spherical ball 142 of a~n appropriate diarrieter may be set in the seat profile 132 at the interior edge of tine send sleeve 46. 'ihe spherical taali i42 will seat arrci seat the sensor device when tree pressure is greater an the inside of the casing string 2t7 the at the oe~tsirie of the t~sirsg string ~0.
z o In the embodirrEent having a porous acre acting as the filter media 13a, the sensor device 26 cornprlses generally a sleeve 46 lyavvityg~ a plurstity of staireiess steel metal beads that are bonded therela with a powder cr~nsistittg of phospharaus, ctuomium, iron, and nickel $txroundir~ the sensor 136. The rx,~ pc~wd~ (,~
shown) is referred to as a 8Ni-? compound and irt cute embotfimant comprises of approximately 4% phosphorous, 17% chromium, 7 % iron and 79% nickel. In another embodiment, the brazing powder may contain at least 1 % phosphorous, at least 10% chromium, at least 0.5% iron and at least 60% nickel.
A brazing process is utilized to manufacture the filter media 135 in the sleeve 46. In other embodiments, the beads could be selected from a group consisting of chromium, ceramic, silica, titanium, andlor copper. The filter media 135 made from this brazing process results in a core that is very porous and highly permeable.
Also, the core exhibits significant compressive strength, an important factor for deployment since the sleeve will undergo significant tensile and compressive forces 1 o at that time.
The beads are sized to optimize sand control performance. In other words, the beads should be sized to prevent formation sand migration into the internal diameter of casing 20, but also allow for the maximum porosity and permeability of the core 135 so that production of the reservoir fluids and gas is maximized.
3. The sensor device As seen in figures 2 and 4, the sensor device 136 may be of any type depending on the desired function to be accomplished. Common parameters required for downhoie operations include, but not limited to, monitoring wellbore temperature, pressure, fluid flow rate and type, formation resistivity, cross-well and 2 o acoustic sesmometry, perforation depth, fluid characteristic or logging data. With the addition of a sensor 136 to the sensor device 26, and a microprocessor 141 provided for analyses, and a control module for pertorming an operation downhole, the reservoir performance may be greatly enhanced by providing instructions to other equipment located downhole to perform certain tasks or functions. For _._...~ t._ example, flow of hydrocarbon production may be adjusted in a particular zone to increase production in another zone. Another example includes finding the best route for a subsequently constructed branch wellbore. !n such a situation, a wellbore has been under production for sometime and is about to deplete a certain zone.
In such cases, reservoir data gather over a period of time is very useful in pinpointing the location of a new branch wellbore to another zone or reservoir. The adjacent reservoir is most efficiently accessed through the original wellbore by determining well characteristics and drilling a branch wellbore from the existing wellbore for accessing the new hydrocarbon reservoir.
1o One or more sensors 136 may be placed in the sensor device 26 depending on the operator's needs and the type of data required for a particular well being exploited. In some cases, one sensor may be sufficient to measure several characteristics, and in other cases, several sensors may be necessary to take adequate readings. In other cases, flow may be necessary. However, it must be noted that flow characteristics may diminish with increasing number of sensors in a single sensor device 26. In order maximize efficiency in the placement of sensors, a plurality of sensor devices 26 may be provided containing disparate sensors as needed. Examples of sensors depending on the parameter to be sensed include:
acoustic sensors, seismic sensors, strain and stress gages, transducer, or any other 2o sensor. A sensor herein is broadly defined as an information pick-up or data retrieval device. It is a component the may convert chemical, mechanical or heat energy into an electrical signal either by generating the signal or by controlling an external electrical source. It may be a transducer designed to produce an electrical output proportional to some time-varying quantity or quality as temperature, pressure, flow rate, fluid characteristic, formation characteristic and so forth. As previously discussed, the level of sophistication of available sensors only increases each day, i.e., MOSS sensors are only the latest in a line of sophisticated sensors available today.
4. Utilization of the invention in welibore testing completion and production operations Any number of downhole operations may be performed which are associated with well testing, well completion procedures and/or maintaining well production by monitoring and/or activating localized operations. For example, the following 1 o functions may be performed: ( 1 ) water shutoff operations at a particular zone; (2) maintaining desired performance of a well by monitoring wellbore parameters such as pressure, temperature, flow rate or any other similar characteristic; (3) initial zone mapping on a cumulative basis using data sensed along the wellbore length during well testing operations; (4) pertorming flow control operations among various zones after sensing various wellbore parameters; (5) performing completion operations such as spacing the casing string and its associated perforations to provide the most efficient placement of flow ports in a multiple zone wellbore with the sensed data of any characteristic; (6) sensing perforation characteristics during completion operations to maximize hydrocarbon production; (7) sensing any number of reservoir 2 o characteristics during an initial testing phase of a wellbore; and/or (8) any number of other operations during the testing, completion and production phases of a wellbore.
5. Electronic communication methods and apparatus The testing, monitoring and controlling of a wellbore target zone 24 may be accomplished by the wellbore operator from the surface 2 when the sensor device __..... W__ ..... . t 26 is associated with a communication system allowing transmission of sensed data between the downhole location 28 of the sensor device 26 to the surface location 2 and vice versa. The monitoring and/or controlling system of this sensor device comprises a surface control system or module comprising central processing unit s (not shown) and one or more downhole monitoring and/or control systems located near a target zone 24 in a wellbore. The downhole monitoring system comprises a sensor device 26 containing at least one sensor. A downhole controller system is provided in addition thereto for performing a required task in response to a signal transmitted from the surface 2 by the wellbore operator through the central Zo processing unit.
In an alternate operation, a completion string 20 may be equipped with a central processing unit (microprocessor 141 ) at a downhole location 28 near the sensor device 26 for a closed loop operation. In this case, a sensed wellbore parameter signal is received from the sensor 136 and transmitted to a 15 microprocessor 141. The microprocessor 141 then uses the relayed signal to execute pre-programmed instructions in response to the received signal. An appropriate instruction signal is then forwarded to a downhole control system located in the wellbore to perform a required function. In accordance with a preferred embodiment of the present invention, the downhole monitoring and/or controlling 2 o system comprises of at least one downhole sensor, a downhole microprocessor 141 and at least one downhoie electro-mechanical control module which may be placed at different locations in the wellbore to perform a given task. Each downhole monitoring and/or controlling system has a unique electronic address. Further, the microprocessor may be asked to verify its analysis with a wellbore operator at the m surface.
The eletltronic communication and control methods and apparatus are discussed and explained in great detail in the applicant's pending applications: {1) U.B. Patent No. b,732,776 $n~t<ed "Downhole production well control system and ~ method"; 2nd (2) U.S. Patent No. 5.81,4$0 entitled "Method and apparatus and recording of operating conditions of a downhole drill bit during drilling operations".
It is apparent frorra these applications that the Communication methods could be through microwa e, electromagnetic, aGOUStic:, NMR or even hardwired technologies. it should ire apparent to those skilled in the art that the novelty Qf the ~0 present invention does not lie in ttre electronic communication method, by itself, used between a downhole location and a surface location, or in the alternative, a communication method in a localized dnwnhate area. Instead, the novelty lies, at least in part, in the use of sensor devices far petfiorming specffiG functions during weltbore production andlor exploratory phases. The sen~>c~r devices may exist in a 15 predetermined symmetry intermittently o~ continuous depending on the welibore Characteristics culminating in a novel and efficient techniques in wellbore testing, completion and production which haretoforE were not available resr~tting in many disadvantages described previously. The presE~nt invention provides many advantages over the prior art testing, completion and production ted~niq~s as described herein previously. The v ovelty further lies in the ability of a wellbore operator to maximize efficient hydrocarbon production by eliminating many aspects of wellbore testing and completion methods to thereby greatly reduce costs for the operator.

6. Alternative embodiments As can be seen in Fig. 2, the housing 42, with the first sleeve 44 and second sleeve 46 are telescoped so that the sensor device 26 is in a retracted position. It should be noted that it is not necessary to have the sensor device 26 comprising three tubular members as described herein. Such an embodiment is only described to herein as the preferred embodiment. The sensor device 26 may function equally with a single tubular member mounted in a threaded fashion or by other means on the casing string 20 containing a sensor 136, a microprocessor 141, and a transmitter (not shown) without departing from the spirit of this invention.
It is clear to one skilled in the art that various methods and designs may be undertaken for is mounting probes containing sensors on casing strings - whether they be retractable, simply surface mounted flush against the tubing wall, or one-time extending probes.
In the alternative, the sensor device may be operatively associated with an adjustable choke or a valve (ball) or a flapper or a "Drill-Stem Testing"
valve. For example, the sensor device 26 in the adjustable choke or ball valve may be activated 2 o upon mechanical or pressure sensitive control or activation systems. Many examples of these type of conventional valves are available from Baker Oil Tools, a company owned by the applicant. The design of the probe is not critical to the operation of this invention.

7. Sensor device perfonninQ sensor operations The downhole control systems 150 will interface with the surface system using wireless communication or alternatively through an electrical wire (i.e., hardwired) connection or any one of the previously described methods. The downhole systems in the wellbore can transmit and receive data and/or commands to or from the surface and/or to or from other devices in the wellbore. The downhoie controller acquires and processes data sent from the surface as received from a transceiver system and also transmits downhole sensor information as received from the data acquisition system comprising the sensor devices 26 and/or memory device 232 and/or microprocessor 141 and also transmits downhole sensor information as received from the wellbore.
Referring now to figure 3, an electrical schematic of a downhole controller 150 is shown. The data acquisition system will preprocess the analog and digital sensor data by sampling the data periodically and formatting it for transfer to the is microprocessor 141. Included among this data is data from flow sensors 136, formation evaluation sensors 142, and/or electromechanical position sensors 151.
The electromechanical position sensors 151 indicate the position, orientation and the like for the downhole tools and equipment.
The formation evaluation data is processed for the determination of the 2 o reservoir parameters related to the well production zone being monitored by the downhole controller 150 andlor tested in the case of an exploratory well. In addition, data may be readily obtained as to reservoir conditions to map alternative branch wellbores. Also, sensors will pick-up information on reservoir content and depletion rates.
_T

The flaw sensor data may b~ pcoct~ed and evraluated against parameters stored in the dwmhoie module's tnemcxy to dekermirte if a oorxiitiQn exists wt~iioh requires the intervention of the processor elecGtora9cs 'F 4 l to automatically tt"re electrornectianicel devices 1 ~. The r~mhale sensors rrvay inciu~ie, but not limited to, sensors far sensing pressure, flow, temperature, oiilwater corderft, gecatogicat torrnation characteristics, gamma ray detectors and irxmaton evaluation ser~rs whic~~ utiti~e acoustic. nuclear. resistivity and eiectromacfnetaa techno~loc~y.
The downhole c~onfrt~lfer 950 ~ may autamatic.alty execute instructions for actuating electromechanical drivers 1a4 or other electronic devices far t~antrotiirx,~
~.p dpwnhate toils such as a sliding sleeve valve, stiut~ff device. valve, variakste d~oke,lt penetrator, perf valve or a gas lift tool In addition, tt~e dowrthole corttroiJer ~5t3 is capable of recording downh~ie data acquired by flow sensors 136, formation evaluation sensors 7~2 and the eiechar~cat position sensors 951 in the rr~mory device 232. The Z~ rnicropracessor 111 pn~rides the cantrvl and ~racessi~ng capabilities of the system downhole. The processor' wits corrtroi the data 2rcquisituon, the dateprocessing, ~1d the evaluatirut oil the d~a for determination if it is within die proper operating ranges.
The rontrolter 151 will also prepare the data for transmission to the surface, end drive the trar~mitter to sated the infarnvattan ta~ ttre ~. ~ processor 141 also f7as the respcxtsit~fity of costtrolling ttte eiectromic~i devices. the analog to digital converter l 5~ transforrr~ the data from tha conditioner citrx~ibry in a binary rxxrrber. 'fhhat tsinary number relates to an etedsiCal current or voltage value used to designate a physical parameter acquired from #t~e gr~oiogit~l fonn~tion, the fluid flow, or the status of tha electrrmte~aniCal devices. Ttte analog cvr~ctitir~n oz CA 02259176 1998-12-24,: -.. . . .
~ n s ~ . . . , ~ w ~ .. . s . . v , a s . v a . .
. v . w. ..~, a ~» ... .., .
hardware153 processes the signals from the sensors into voltage values that are at the range required by the analog to digital converter. The digital signal processor 152 provides the capability of exchanging data with the processor to support the evaluation of the acquired downhole information, as well as, to encode/decode data for the transmitter (not shown). The processor 141 also provides the control timing for the drivers 156. The communication drivers 156 are electronic switches used to control the flow of electromechanical power to the transmitter. The processor provides the control and timing for the drivers 156. The serial bus interface allows the processor 141 to interact with the surface acquisition and control system i o (not shown). The serial bus allows the surface system to transfer codes and set parameters to the downhole controller to excecute its functions.
Placement of the microprocessor 141, whether it be in the sensor device 26 itself or in the alternative, at a nearby location in the casing string is dependent on the complexity of operations to be conducted downhole. In an operation involving, i5 closed loop operations, a Miniaturized Optimized Processor for Space -or MOPS6000 is available from the Southwest Research Institute. The RAD6000 is an ultra compact computer, approximately, 300 cubic centimeters in size with grams in weight, and capable of delivering 25 million instructions per second.
Thus, a single microprocessor 141 optimally located in the casing string could feed 2o instructions for°all of the plurality of sensors mounted on the casing string. The location itself could be in one of the sensor devices 26 or in the alternative along a portion of the~~casing. The sensors 26, in turn, may be located in a predefined symmetry ai~ng the casing string and linked to the microprocessor 141.
Instructions are then issued to electromechanical devices 158 located nearby or at a distance AMENDED SHEET
IPE~/EP

from the microprocessor 141. These electromechanical control devices manipulate various conditions of wellbore performance. In addition, all uses presently provided by wireline operations may be conducted by existing sensors already in place along the casing string.
In addition, a Space Adaptable Memory module (SpAMM), also available from the Southwest Research Institute, is ideal for downhole operations by providing dense, scalable, nonvolatile gigabyte mass memory in a small light weight package.
High-density multi-chip modules and staked memory dies are used in SpAMM to deliver a memory density of 84 megabytes per cubic inch.
1o Thus, certain data may be gathered and stored white other data used immediately for operations. It becomes clear to one skilled in the art that permutations of data to be used will depend on a myriad of operations to be performed. Well logging may be well suited for the memory device 232 while temperature, pressure and flow characteristics are more adapted to be used immediately to control wellbore performance. The memory device 232 is better suited for exploratory well data used during drilling operations of subsequent branch wellbores. The information gathered itself could be a myriad of possibilities.
For example, data could relate to the wellbore itself, other nearby wellbores, single or multiple reservoirs, multiple zones in a single reservoir or cross-well information 2 o relating to all of the above.
When using a memory device 232 downhole, the stored data information may be retrieved by any number of methods. For instance, data may be retrieved when a well is being worked over. At this time, the well is easily accessible and therefore data retrieval equipment may be deployed to retrieve the data information from the memory device 232. However, information stored in the memory device 232 is normally more useful if it is capable of being retrieved during periods when the wellbore is in operation. During these periods, the invention is equally accessible for data retrieval through using real time communication methods to transfer data from a downhole location to the surface or to transfer it to a microprocessor 141 for processing and then to a control system.
During other times, a data retrieval mandrel 230 may be deployed downhole through the production tubing 209 to retrieve the stored data information on the wellbore and/or fluid characteristics. Referring to figure 3, the mandrel 230 is 2 o designed to be aligned with the sensor devices 26 and the attendant memory device 232. The mandrel 230 is equipped with an information pick-up device 231 which are aligned either with the sensors 26 or the memory device 232. Once aligned, the information may be transferred selectively as needed. Alternatively, a memory device 233 may be located in the mandrel 230 which collects the data directly from the sensor devices 26. The memory device 233, if necessary, could also store information collected from the downhole memory device 232 but the preferred method is to transmit data to the surface directly. Also a microprocessor 234 located within the mandrel 230 may selectively perform required action while located downhole.
2 0 8. Extending the Sensor Device to the Wellbore Wall In pertorming wellbore operations, activation of the sensor device to extend to the wellbore wail may be accomplished by any number of methods. For example, the sensor device may be activated (extended) by electronic methods, mechanical methods or in the alternative through the use of hydrostatic pressure.
Existing _ T

technology has offered either of the later options. For example, mechanical activation is achieved through a mechanical activation member which may be a wiper plug (not shown). The wiper plug is lowered down into the casing string until the wiper plug contacts the first sleeve 44 which will cause both the first sleeve 44 and second sleeve 46 to move from a retracted position to an intermediate position locking it from backward movement, as well as, locking the first sleeve 44 in an extended position. The wiper plug is pumped down using conventional techniques such as those used during cementing operations. The sensor may be utilized during any portion of this mechanical activation to obtain any number of 1 o wellbore characteristics. Use of downhole data during various operations is only limited by the users creativity and needs.
Hydraulic pressure is then applied to the internal diameter of the casing string 20. The hydraulic pressure applied on the sensor device forces the second sleeve 46 to extend outwardly towards the formation wall 25 as seen in Fig. 4. The second sleeve 46 will proceed outwardly until either the outer end of the sensor device 26 surface contacts the formation wall 25 or until all ratchet pawls have fully extended past the detent 1398. Again, use of the sensor 136 to obtain any data during any portion of the operation is possible. The parameter or data obtained is only limited by the needs of an operator.
2 o The entire sensor device 26, including the first 44 and second sleeve 46, may be also extended by purely hydraulic means in the event that the mechanical means is not practical or undesirable. In such a case, the wellbore operator would pump down the casing string a composition that coats the sensor device 26 when designed to allow flow through a filter media 135, or alternatively, a soluble/impermeable compound may be placed on the f Iter media 135 at its interior surface. The composition used to form an impermeable barrier is of a type conventionally available from Baker Hughes Incorporated under the trademark PERFFLOWT"".
The internal casing string pressure forms a filter cake from the composition, such as PERFFLOWTM, on the core surface of the filter media. The hydraulic pressure acting against the impermeable barrier and the core surface of the filter media deploys the first and second sleeves as described previously.
As previously discussed, sensor data may be utilized in any number of ways depending on the needs of the operator. For example, flow characteristic may be an to important criterion during the coating operation to maximize efficiency. A
flow sensor would provide data to the operator as to when a particular sensor device is completely coated so as to stop transmitting the coating compound.
Similarly for certain acidizing operations, a sensor 136 in the sensor device 26 may provide ideal data for conducting efficient and time-saving operations.
During acidizing operations, the a spherical ball (not shown) is provided in the seat profile 132, as seen in figure 4, for sealing engagement with the sensor device 26 preventing flow. If it is determined that a sensor device 26 requires acidizing operations because of poor hydrocarbon flow characteristics as detected by the sensor 136, then it may be necessary to send a diverting ball downhole which seeks 2 0 out the seat profile in the sensor device 26 having a low pressure drop across it.
Acid is then pumped down the casing string 20. The acid is diverted away from a sensor device having high pressure drop across it (indicating good flow condition) because the diverting ball seals the sensor device 26 along the seat profile 132. The diverting ball by-passes a sensor device having a low pressure drop because the I

hydraulic pressure is great enough to sustain a downward movement of the diverting ball. Increasing the internal pressure of the casing string 20 causes the diverting ball to seal against the chamfered surface 132.
Conventional ball injector systems are commonly available in the oilfield s industry. This technique may be utilized throughout the life of a wellbore, especially when it is necessary to perform remedial acidizing andlor fracture stimulation of a wellbore to maintain maximum hydrocarbon production. In all of these operations, the sensors 136 may be used in creative ways to monitor any wellbore parameter during any portion of the procedure. The use of the sensor 136 to utilize data for a so particular condition is only limited by the user's creativity.
9. Multiple Zone Testing:
Referring now to Fig. 6, the method of testing an exploratory well will now be described in a multi-zone testing operation. Again, in this type of an operation, the sensor 136 located in the sensor device 212 provides ideal opportunity for the 15 retrieval of necessary data to maximize efficiency during exploratory operations while eliminating certain unnecessary prior art procedures. A particular advantage provided by the sensor in the sensor device is the provision of "real time"
data during exploratory phases in wellbore operations. This "real time" data may be utilized in performing any number of operations during the exploratory phase. In the 2 o alternative, localized closed loop operations may be also be performed depending on the needs of the operator after detection of the pre-determined request for data is satisfied and analyzed by a local microprocessor 141.
The method includes first positioning in the exploratory well a casing string 200. The casing string 200 intersects a series of target reservoirs 204, 206, respectively. A testing work-string 209 is also run into the well which includes a packer member 210 that is capable of multiple setting along the wellbore length. The testing work-string 209 will also contain a valve member 211 capable of movement from an open position to a closed positioned within the work-string 209.
The position of the bottom-hole assembly 202 is then correlated as the work-string 209 is run into the casing string 200 in the wellbore so that the bottom-hole assembly 202 is adjacent a lower-most target reservoir 204. In the preferred embodiment, open-hole logs are first recorded, and therefore, the location of a test hydrocarbon zone will be known. Thus, casing string 200 containing multiple sensor 1o devices may be positioned at the appropriate depths adjacent each hydrocarbon production zone through selectively using the sensor 136 in each sensor device 212, 214, 216, respectively. Thus, using the sensor 136, each sensor device may be activated at localized production zones, thus efficiently completing the wellbore construction with the necessity of multiple trips into the wellbore.
This type of a wellbore completion maximizes hydrocarbon production from the wellbore while preventing sand production. A plurality of sensor devices may be provided for each isolated zone which are spaced about the circumference of the casing string 200. Spacing the sensor devices axially along the casing string 200 as needed further maximizes zone identification and positioning.
2 o A packer member 210 seals the inner diameter of the work-string 209 from the lower end of the casing string 200 thereby forming an upper annulus 218.
In the example depicted, the lowest sensor device 212 is activated to an extended position so that the sensor device 26 contacts the target reservoir 204. In the preferred embodiment, the means of activating the extendible sensor device is through the two _...T _.

steps hydraulic method previously described. The soluble compound coating the sensor device 212 having a filter media 136 will then be dissolved by pumping an acid solution down the inner diameter of the work-string 209. Because the packer member 210 is set, the acid solution will be diverted through the inner diameter of the work-string 209 and into the sensor device 212 establishing fluid communication with the production zone 204.
Thus, once the sensor device 212 is extended and the soluble compound dissolved, the hydrocarbon zone 204 may be tested by flowing the target reservoir 204 by opening up the valve 211. Multiple flow and pressure build-up tests may be 1o performed by opening and closing the valve 211.
As can be seen by one skilled in the art, obtaining "real time" data for surface manipulation of a certain operation using such data greatly improves efficiency while eliminating certain procedures entirely. In the alternative, localized operations are similarly performed by analyses of incoming data in closed loop operations using a microprocessor 141 and control mechanisms.
Testing other hydrocarbon zones may be similarly accomplished by moving the work-string to the intermediate zone position using the sensor 135 located in each sensor device. The isolation packer 210 member is the set at the appropriate depth using the electronic control system previously described for isolating the 2 o wellbore. The isolation packer 210 member is located at a position above the lower target zone 204 but below the intermediate target zone 206, and allowing flow from both the lower target reservoir 204 and the intermediate target zone 206.
Necessary flowing periods followed by shut-in periods as is well known in the art may be also accomplished using the data obtained through the sensor 136 in a given sensor device. Again obtaining data fog a particular characteristic clearly provides advantages over prior art technology for performing similar operations.
Alternately, as seen in Figure 6, the method may further comprise the step of shutting-in a particular target zone such as, for example, zone 204 in Figure 6 by an isolating member (not shown) such as a through-tubing bridge plug. The through tubing bridge plug is run through the work-string 209 and positioned above the reservoir 204 so that the lower zone is now isolated.
Alternately, a plurality of balls that fit and seal-off the sensor device along the circumference surface 132 may be pumped down to isolate it. The packer member l 0 210 is re-set at a repositioned up-hole position indicated at 226 in Figure 6 under these operations. The sensor device 214 is then hydraulically extended as already described. The soluble barrier 134 may be dissolved by pumping an acid slurry.
Again, a flowing and pressure build-up test may be performed by manipulation of the valve 211. If it is determined that some of the perforations require acidizing because of poor hydrocarbon flow, then it may be necessary to pump a plurality of diverting balls 142. These diverting balls 142 would seek out and seal those sensor devices having poor flow conditions as previously described herein by monitoring low pressure drops. The acid is diverted to those devices having high pressure drops to dissolve clogging material to thus improve flow conditions. Once again obtaining 2 o data for a particular characteristic clearly provides advantages over prior art technology for performing similar operations.
Changes and modifications in the specifically described embodiments may be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims.
T

Claims (53)

What is claimed is:

1. A device for monitoring a reservoir in a wellbore, said wellbore having at least one target formation and having a tubular member comprising casing or production tubing, said device for monitoring further comprising:

at least one sensor comprising an information retrieval device, being mounted on the tubular member on a probe such that said sensor is retained substantially within said tubular member until it is positioned adjacent the target formation whereupon said probe is extendable with said sensor to position said sensor adjacent the target formation for gathering wellbore characteristic data therefrom.

2. The device of claim 1, further comprising:
a plurality of sensors mounted in a predetermined symmetrical pattern along the length of the tubular member.

3. The device of claim 1, further comprising:
a plurality of sensors mounted on the tubular member for monitoring a hydrocarbon reservoir in the target formation.

4. The device of claim 1, further comprising:
a plurality of sensors mounted on the tubular member for monitoring reservoir fluid in the target formation.

5. The device of claim 1, further comprising:
a plurality of sensors mounted on the tubular member at predetermined angular positions around the tubular member.

6. The device of claim 5 wherein:

said plurality of sensors are positioned around the tubular member in an isotropic manner for sensing formation characteristics in all directions of the wellbore.

7. The device of claim 9, further comprising:

a plurality of sensors positioned on the tubular member in a straight line along a portion of the tubular member's axis length.

8. The device of Claim 1, further comprising:

a plurality of sensors in a plurality of probes which measure resistivity of the formation when extended toward the sidewall of the wellbore.

9. The device of claim 1 wherein:

the information retrieval device is capable of monitoring chemical, mechanical, electrical or heat energy located in an area adjacent the sensor.

10. The device of claim 1 wherein the sensor monitors any one of the following wellbore characteristics:

temperature, pressure, fluid flow, fluid type, resistivity, cross-well acoustics, cross-well seismic, perforation depth, fluid characteristic and logging data.

11. The device of claim 1 wherein:

said sensor transmits a sensed wellbore characteristic data signal to a microprocessor at a surface location.

12. The device of claim 11 further comprising:

a memory device located an the tubular member for storing the wellbore characteristic data signal received from said sensor.

13. The device of claim 1 wherein said sensor is located on the production tubing in an open-hole wellbore completion.

14. The device of claim 1 wherein said sensor is located on the caging in a cased-hole wellbore completion.

15. A device for monitoring a reservoir in a wellbore comprising:

a tubular member being received in the wellbore adjacent a target formation;

one or more screen liners mounted along the tubular member;

at least one sensor, comprising an information retrieval device, being mounted an the tubular member and positioned at predetermined intervals along the length of the tubular member;

at least one sensor, each comprising an information retrieval device, being mounted on the screen liner and positioned at predetermined intervals along the length of the liner; and the tubular member being positioned in the wellbore to extend adjacent the target formation for gathering wellbore characteristic data therefrom,

16. An apparatus, for performing one of wellbore testing, completion and production, which is in communication with a target reservoir in a wellbore comprising:

a tubular pipe having an aperture for communicating with the target reservoir, and at least one flow control device moveably mounted within the aperture of the tubular pipe for receiving fluid flow from the wellbore comprising:

a tubular member moveably mounted on the tubular pipe for movement in a direction generally along the tubular member's longitudinal axis between a retracted position primarily within the tubular pipe and an extended position towards a sidewall of the wellbore near the target reservoir; and, a sensor device located in the tubular member for selectively monitoring a wellbore parameter.

17. The apparatus of claim 16, wherein:
said tubular member further comprises a filter media therein; and said tubular member is selectively operable in a first made blocking fluid flow and in a second mode enabling fluid flow from the target reservoir into the tubular pipe.

18. The apparatus of claim 17 wherein:

the flow control device selectively monitors the wellbore parameter independently of whether the side-wall of the wellbore engages the flow control device.

19. The apparatus of claim 17 wherein:
the sensor device comprises an information retrieval device capable of converting electrical, chemical, mechanical or heat energy into an electronic signal.

20. The apparatus of claim 17 wherein:
the sensor device comprises at least one from a group of the following:
seismic receiver, an acoustic receiver and a mechanical receiver.

21. The apparatus of claim 17 wherein:

the flow control device monitors any one of the following wellbore parameters:

temperature, pressure, fluid flow, fluid type, resistivity, cross well resistivity, perforation depth, fluid characteristic and logging data.

22. The apparatus of claim 17 wherein:
the sensor device transmits a wellbore parameter data signal to a microprocessor at a surface lotion.

23. The apparatus of claim 22 wherein:
the microprocessor after processing the received wellbore parameter data signal transmits a signal to implement a central instruction to a downhole control device.

24. The apparatus of claim 17 wherein:
the sensor device transmits a wellbore parameter data signal to a memory device located an the tubular pipe for storage of the data signal.

25. The apparatus of claim 17 further comprising:
a microprocessor located downhole on the tubular pipe, after processing a received wellbore parameter signal from the sensor device, transmits a signal to a downhole control device to implement a control instruction.

26. The apparatus of claim 25 wherein:
the microprocessor transmits the processed data signal to the surface along with a request for approval from the surface location to implement the control instruction.

27. The apparatus of claim 26 wherein:
the surface location transmits a decision signal to the microprocessor to either implement or ignore the control instruction.

28. The apparatus of claim 25 wherein:
the surface location transmits an action signal to the microprocessor to perform a required action independent of the processed data signals.

29. The apparatus of claim 17 wherein:
the filter media comprises a plurality of beads consolidated by a handing agent to form a fluid permeable care.

30. The apparatus of claim 29 wherein:
the consolidated beads comprise a metal alloy and the banding agent is a brazing powder.

31. The apparatus of claim 17 wherein:
the fitter media further comprises a dissolvable material located in interstitial pores of the filter media for preventing fluid flow when present in the filter media.

32. The apparatus of claim 17, further comprising:
a plurality of flow control devices containing sensor devices, said flow control devices disposed on the tubular pipe.

33. A method of wellbore completion, including a method for monitoring a wellbore parameter during hydrocarbon production, comprising:

positioning a tubular into a wellbore, having a sensor devise movably mounted for receiving a wellbore parameter signal and having fluid communication with a target reservoir;
correlating the position of the sensor device with the target reservoir so that the sensor device is adjacent the target reservoir, extending the sensor device toward the target reservoir from a retracted position to an extended position;
sensing a wellbore parameter signal from the subterranean formation by way of the sensor device;
transmitting the wellbore parameter signal from the sensor device to a microprocessor;
processing the wellbore parameter signal with the microprocessor; and transmitting a control signal from the microprocessor to a control device located downhole for carrying out a command instruction.

34. The method of claim 33, further comprising:
providing selective communication into the tubular through said sensor device;
enabling selective flow into the tubular past said sensor device; and receiving a wellbore parameter signal from the reservoir fluid in the formation.

35. The method of claim 34 further comprising:
transmitting the processed data signals to the surface location along with a request for approval from the surface location to implement the control instruction.

36. the method of claim 35 further comprising:
transmitting a decision signal from the surface location to the microprocessor to either implement or ignore the control instruction.

37. The method of claim 33 further comprising:
transmitting an action signal from the surface to the microprocessor to perform a required action independent of the processed data signals.

38. A method of testing an exploratory well leading to a target reservoir, comprising:
positioning in the exploratory wellbore a tubular having at least one flow control device for receiving selective fluid communication from an adjacent target reservoir, the flow control device comprising:
an extendible member, containing a filter media allowing selective fluid flow, extendible from within the tubular in a retracted position to an expanded position toward the wellbore wall;
a sensor device located within the extendible member for receiving wellbore parameter signals;
correlating the position of the flow control device so that it is adjacent the target reservoir;
activating the flow control device so that the extendible member moves toward the wellbore wall;
testing the hydrocarbon zone by flowing the target reservoir through the filter media into the tubular;
receiving a wellbore parameter signal using said sensor device;
transmitting the wellbore parameter signal to a microprocessor and processing the signal; and sending a control instruction to a control device located within the wellbore for performing a control operation.

39. The method of claim 38 further comprising:
transmitting the processed data signal to the surface location along with a request for approval from the surface location to implement the control instruction.

40. The method of claim 39 further comprising:
transmitting a decision signal from the surface location to the microprocessor to either implement or ignore the control instruction.

41. The method of claim 38 further comprising:
transmitting an action signal from the surface to the microprocessor to perform a required action independent of the processed data signals.

42. The method of claim 38, wherein the exploratory well contains a lower, an intermediate, and an upper target reservoir, and wherein the tubular is positioned in the wellbore so that flow control devices correspond to depths of the lower, intermediate and upper target reservoirs and wherein the method of testing each of the hydrocarbon zones comprises:
lowering a tubular string having thereon a control device comprising an isolation packer for isolating the wellbore;
setting the isolation packer at a position above the lower target reservoir but below the intermediate target reservoir; and flowing hydrocarbon production into the tubular from the lower target reservoir by activating at least one flow control device adjacent to it.

43. The method of claim 42, further comprising:
shutting-in the well by activating a bridge plug in the well at a point above the lower target reservoir;

releasing and repositioning the isolation packer to a point above the intermediate reservoir;
setting the isolation packer at a position above the intermediate target reservoir; and flowing hydrocarbon production into the tubular from the intermediate target reservoir by activating at least one flow control device adjacent to it.

44. The method of claim 43, further comprising:
shutting-in the well by activating a bridge plug in the well at a point above the intermediate target reservoir;
releasing and repositioning the isolation packer to a point above the highest reservoir;
setting the isolation packer at a position above the highest target reservoir;
and flowing hydrocarbon production into the tubular from the highest target reservoir by activating at least one flow control device adjacent to it.

45. A device for monitoring a reservoir in a wellbore, said wellbore having at least one target formation and having a tubular member comprising casing or production tubing, said device for monitoring further comprising:
at least one sensor comprising an information retrieval device, being mounted on the tubular member and positioned on the tubular member adjacent the target formation for gathering wellbore characteristic data therefrom;
at least one extendible probe mounted on they tubular member having a sensor, said probe extended toward the sidewall of the wellbore when it is in a fully extended position; and said probe receives fluid flow from an adjacent formation.

46. the device of claim 45 wherein:
the extendible probe is operatively associated with a flow control mechanism for preventing flow in a first mode and permitting flow in a second made.

47. The device of claim 45 wherein:
the extendible probe is operatively associated with a flow control device for variably controlling the flow rate into the tubular member from the adjacent formation.

48. A device for monitoring a reservoir in a wellbore, said wellbore having at least one target formation and having a tubular member comprising casing or production tubing, said device for monitoring further comprising:
at least one sensor comprising an information retrieval device, being mounted on the tubular member and positioned on the tubular member adjacent the target formation for gathering wellbore characteristic data therefrom;
at least one housing defining a flow passage into the tubular member for receiving fluid flow from the reservoir and wherein said housing contains a filter media for retention of at least some of the particulate matter; and wherein said housing has a sensor in said housing for sensing fluid properties.

49. A device for monitoring a reservoir in a wellbore, said wellbore having at least one target formation and having a tubular member comprising casing or production tubing, said device for monitoring further comprising:
at least one sensor comprising an information retrieval device, being mounted on the tubular member and positioned on the tubular member adjacent the target formation for gathering wellbore characteristic data therefrom;

said sensor transmits a sensed wellbore characteristic data signal to a microprocessor at a surface location; and the microprocessor, after processing the received wellbore characteristic data signal, transmits a signal to implement a control instruction to a downhole control device.

50. A device for monitoring a reservoir in a wellbore, said wellbore having at least one target formation and having a tubular member comprising casing or production tubing, said device for monitoring further comprising:
at least one sensor comprising an information retrieval device, being mounted an the tubular member and positioned on the tubular member adjacent the target formation for gathering wellbore characteristic data therefrom; and a microprocessor mounted with said sensor for processing at least one data signal received from said sensor and for transmitting said signal to implement a control instruction to a downhole control device.

51. the device of claim 50 wherein:
the microprocessor transmits said processed data signal to the surface along with a request for approval from the surface location to implement the control instruction.

52. The device of claim 51 wherein:
the surface location transmits at least one decision signal to the microprocessor to either implement or ignore the control instruction.

53. The device of claim 51 wherein:

the surface location transmits at least one action signal to the microprocessor to perform a required action independent of the processed data signals.