CA2628766C - Downhole array and assembly thereof - Google Patents

Abstract

A downhole array includes a plurality of canisters, a component disposed in each of the plurality of canisters, and at least one conduit coupling the plurality of canisters The canisters are spaced apart from one another by one or more predetermined distances. A downhole array assembly includes a tubing string, a plurality of canisters disposed within the tubing string, and a plurality of couplings corresponding to the plurality of canisters, one of the plurality of couplings attaching a corresponding one of the canisters to the tubing string. The downhole array assembly further includes a component disposed in each of the plurality of canisters and at least one conduit coupling the plurality of canisters. The canisters are spaced apart from one another by one or more predetermined distances and the tubing string is contiguous proximate the plurality of canisters

Description

119.0003 DOWNHOLE ARRAY AND ASSEMBLY THEREOF

BACKGROUND OF THE INVENTION
Field of the Invention [0001] The present invention relates to downhole arrays configured for use in wells, such as oil and gas wells.

Description of Related Art [0002] It is often desirable to control and or perform operations, such as chemical injection, dewaterization, or gas lifting applications, on a well.
Furthermore, it is also often desirable to determine characteristics of a well or characteristics of fluid to be produced from a well. For example, it is often desirable to gather information, such as reservoir pressure and temperature, about the fluid-producing or "production interval"
of a well. Such information can, then, be used to optimize the production from the well.
In directionally-drilled oil and gas wells, commonly referred to as "horizontal" wells, the thickness and geology of the hydrocarbon-bearing reservoir can vary greatly over the length of the production interval. The importance of these variations is compounded when producing highly viscous oils with high specific gravities, commonly referred to as "heavy oils," which are often recovered using steam-assisted, gravity-drainage (SAGD) techniques. For example, knowing reservoir pressures and temperatures at locations along the production interval allows specific completions and production simulation programs to be designed for particular wells to optimize production from the wells.

[0003] However, current technologies for determining the reservoir pressures and temperatures along production intervals of wells are expensive and often unreliable.
For example, positioning multiple pressure and temperature sensors, as well as other components, such as flow control devices, within a well often creates restrictions in the well. Moreover, pressure and temperature sensors are fragile in nature and, to inhibit failures, must be protected from the often extreme environments found in wells.
Furthermore, data derived from the sensors must be correlated with the locations of the sensors within the production interval for the data to be of any value.
Accordingly, to inhibit the sensors or other such components from drifting from their desired locations within a well, the sensors often must be banded, clamped, strapped, and/or otherwise attached to the well casing. It should be noted that deploying multiple sensors or other such components within a production interval of a well using conventional techniques often requires multiple runs or trips down the well.
Each run adds to the unproductive cost of operating or completing the well.
Moreover, retrieving the sensors from the well interrupts or at least hinders operation of the well.

[0004] There are many designs of downhole component arrays well known in the art, however, considerable shortcomings remain.

BRIEF SUMMARY OF THE INVENTION

[0005] In one aspect of the present invention, a downhole array is provided.
The downhole array includes first and second canisters, a component disposed in each of the canisters, a first conduit extending to the first canister, and a second conduit extending to the second canister such that the canisters are spaced apart from one another by a predetermined distance.

[0006] In another aspect, the present invention provides a downhole array assembly. The downhole array assembly includes a tubing string, first and second canisters disposed within the tubing string, and first and second couplings corresponding to the first and second canisters, each coupling attaching a corresponding one of the canisters to the tubing string. The downhole array assembly further includes a component disposed in each of the canisters, a first conduit extending the first canister, and a second conduit extending to the second canister. The canisters are spaced apart from one another by a predetermined distance.

[0007] In yet another aspect of the present invention, a well is provided.
The well includes a wellhead, a borehole (cased or uncased) extending from the wellhead into a productive interval, and a tubing string disposed in the borehole and extending from the wellhead into the productive interval. The well further includes first and second canisters disposed within the tubing string, first and second couplings corresponding to the first and second canisters, each of the couplings attaching a corresponding canister to the tubing string, a component disposed in each of the canisters, a first conduit extending from the wellhead to the first canister, and a second conduit extending from the wellhead to the second canister. The canisters are spaced apart from one another by a predetermined distance.

[0008] The present invention provides significant advantages, including: (1) providing a way to deploy components in a productive interval of a well without unduly restricting the well; (2) providing a way to protect components from the extreme environments found in wells; (3) providing a way to deploy components in a productive interval of a well without banding, clamping, or strapping the components to a well casing; and (4) providing a way to deploy a plurality of components in a productive interval of a well in one run or trip.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The novel features of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:

[0010] Figure 1 is a side, sectional view of an illustrative embodiment of a downhole array assembly operably associated with a horizontal well;

119.0003 [0011] Figure 2 is a stylized, schematic view of a portion of the downhole array assembly of Figure 1, illustrating predetermined spacing between canisters of the array assembly;

[0012] Figure 3 is a stylized, schematic view of a portion of the downhole array assembly of Figure 1, illustrating exemplary conduit configurations of the array assembly;

[0013] Figure 4 is a stylized, partial cross-sectional view of a portion of the downhole array assembly of Figure 1, depicting an illustrative attachment between a canister and a tubing string of the array assembly;

[0014] Figures 5-8 are cross-sectional views of a portion of the downhole array assembly of Figure 1, depicting various illustrative coupling embodiments for attaching a canister and a tubing string of the array assembly;

[0015] Figures 9 and 10 are stylized, partial cross-sectional views of a portion of the downhole array assembly of Figure 1, depicting illustrative embodiments of a canister of the array assembly;

[0016] Figure 11 is a perspective view of an illustrative embodiment of the array assembly of Figure 1 in a sensor array configuration;

[0017] Figures 12-13 are perspective views of alternative, illustrative embodiments of the array assembly of Figure 1 in a sensor array configuration;
and [0018] Figure 14 is a perspective view of an illustrative embodiment of a canister in the sensor array configuration.

[0019] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that 119.0003 the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another.
Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0021] A downhole array includes a plurality of canisters that are linked or interconnected via a single conduit or a plurality of conduits. The single conduit or plurality of conduits may, in various embodiments, comprise, for example, hydraulic, optical, and/or electrical conductors. The plurality of canisters is not required to be linked in series, as a conduit of the plurality of conduits may bypass one or more canisters. The canisters of the plurality of canisters are spaced away from one another by one or more predetermined distances. Preferably, the one or more conduits define the canister spacing.

[0022] In one embodiment, the array is disposed within and attached to a tubing string to form an array assembly, such that the installation of the array in the tubing string does not appreciably or substantially affect the structural integrity of the tubing string. The tubing string is contiguous proximate the plurality of canisters, such that the only breeches in the tubing string proximate the plurality of canisters are openings used to attach the plurality of canisters to the tubing string and to allow 119.0003 communication of reservoir fluids into the plurality of canisters. In embodiments that include a tubing string, each canister of the plurality of canisters is preferably located within the tubing string using a detection device external to the tubing string. The location of each canister with respect to the tubing string is fixed using an anchoring means.

[0023] The present array is particularly useful in well completion and in reservoir monitoring and control. For example, in well completion applications, the downhole array can, in various embodiments, facilitate packer setting, zonal isolation, chemical injection, dewaterization, gas lift, and/or other such activities.
The downhole array can be configured into a sensor array by the addition of one or more sensors in the canisters of the array. The sensor array can provide sensory information that is useful in determining pressure, acoustic, and temperature characteristics of a reservoir;
fluid sampling; fluid testing; and/or other such activities relating to reservoir monitoring and control. Such sensory information may be gathered in real time or stored with the aid of memory devices.

[0024] Figure 1 depicts a stylized, side, sectional view of a downhole array assembly 101 operably associated with a directionally-drilled or "horizontal"
well 103. It should be noted, however, that downhole array assembly 101 may be operably associated with wells other than horizontal wells, such as wells known as "vertical"
wells. In the illustrated embodiment, downhole array assembly 101 extends from a wellhead 105 proximate a surface 107 of the earth to a location in well 103 within a productive zone or interval 109. As is described in greater detail herein, downhole array assembly 101 of the illustrated embodiment comprises a downhole array 111 including a plurality of canisters 113, 115, 117, and 119 disposed within a contiguous tubing string 121. It should be noted, however, that downhole array 111 may include any suitable number of canisters, such as canisters 113, 115, 117, and 119.
Preferably, tubing string 121 is of the type commonly referred to in the art as "coiled tubing," and tubing string 121 is contiguous in the zone proximate canisters 113, 115, 117, and 119, as discussed above. In some embodiments, however, tubing string 121 is omitted, as 119.0003 discussed in greater detail herein with regard to Figure 14. One or more conduits 123 couple the plurality of canisters. In the illustrated embodiment, the one or more conduits 123 pass through wellhead 105 so that the one or more conduits can be coupled with ancillary equipment. For example, in one embodiment, the one or more conduits 123 provide a means for conducting sensory information from sensors operably associated with the canisters to a location proximate wellhead 105 and provide a means for conducting power to sensors of downhole array 111. Moreover, downhole array 111 may be used as a selective production string to retrieve fluids from productive zone 109 of well 103.

[0025] Figure 2 is a stylized, schematic view, referenced in Figure 1, of canisters 113 and 115 disposed in tubing string 121 and coupled by conduit 123.
Canisters 113 and 115 are separated by a predetermined distance L to provide a desired distance between locations within productive interval 109 (shown in Figure 1). It should be noted, however, that other canisters may be separated by predetermined distances other than predetermined distance L or other canisters may be separated by the same predetermined distance L.

[0026] As discussed above, the plurality of canisters 113, 115, 117, and 119 (shown in Figure 1) may be interconnected, either in series or not in series, by one conduit, such as conduit 123 (shown in Figures 1 and 2), or by more than one conduit.
For example, in the stylized, schematic view of Figure 3, referenced in Figure 1, canisters 115, 117, and 119 are interconnected in the aggregate by conduits 301, 303, and 305, rather than by single conduit 123. In the illustrated embodiment, conduit 301 extends to canisters 117 and 119 but not to canister 115. Conduit 303 extends to canisters 115 and 117 but not to canister 119. Conduit 305 extends to canisters 115 and 119 but not to canister 117. It should be noted that the configuration depicted in Figure 3 is merely exemplary of the multitude of configurations that would be evident to one of ordinary skill in the art having the benefit of the present disclosure, each of which is deemed to be within the scope of the present invention.

119.0003 [0027] Figure 4 provides a stylized, schematic view, referenced in Figure 1, of canister 117 disposed in tubing string 121 with conduit 123 extending through canister 117. Note that tubing string 121 is shown in cross-section. Canister 117 is attached to tubing string 121 by a coupling 401 to fix the location of canister 117 with respect to tubing string 121. Couplings corresponding to coupling 401 also attach canisters 113, 115, and 119 (shown in Figure 1) to tubing string 121. The scope of the present invention encompasses any suitable means for attaching canister 117, as well as the other canisters of downhole array 111, such as canisters 113, 115, and 119, to tubing string 121. In some embodiments, coupling 401 defines a port, represented by arrow 403, providing fluid communication into canister 117, and such embodiments of coupling 401 are discussed in greater detail herein with respect to Figures 5-8. Canister 117 provides pressure integral seals through which conduit 123 passes or to which conduit 123 is connected.

[0028] Figures 5-8 depict cross-sectional views of various embodiments of coupling 401 that may be employed with any tubing string and canister of downhole array assembly 101. Referring to Figure 5, tubing string 121 defines a threaded opening 501 and canister 117 defines a corresponding threaded opening 503. A
threaded plug 505 is threadedly engaged with threaded opening 501 and threaded opening 503 to provide a pressure seal between the inside of canister 117 and the inside of tubing string 121. In the illustrated embodiment, threaded plug 505 defines a port 507 that provides communication of reservoir fluids from outside tubing string 121 to the inside of canister 117. In the illustrated embodiment, reservoir fluids are allowed to enter tubing string 121 and an annulus 509 between tubing string 121 and canister 117.

[0029] Figure 6 depicts an alternative embodiment of coupling 401. Tubing string 121 defines an opening 601 and canister 117 defines an opening 603 that is smaller than opening 601. Canister 117 is attached to tubing string 121 by a weldment 605 that extends contiguously about opening 601 to provide a pressure seal between the inside of canister 117 and the outside of tubing string 121. Opening 603 provides a 119.0003 port 607 for communication of reservoir fluids from outside tubing string 121 to the inside of canister 117. In the illustrated embodiment, weldment 605 further provides a pressure seal between the exterior of tubing string 121 and the interior of tubing string 121, thus inhibiting reservoir fluids from entering tubing string 121 except into canister 117.

[0030] Figure 7 depicts yet another embodiment of coupling 401. Tubing string 121 defines an opening 701 and canister 117 defines an opening 703. A
rivet-style fastener 705 extends between tubing string 121 and canister 117 to fasten canister 117 to tubing string 121. Rivet-style fastener 705 defines a port 707 for communication of reservoir fluids from outside tubing string 121 to inside of canister 117.
In the illustrated embodiment, rivet-style fastener 705 provides a limited pressure seal between the outside of tubing string 121 and the inside of canister 117.

[0031] Figure 8 depicts yet another embodiment of coupling 401. A canister 801 defines recesses 803 and 805 extending circumferentially about canister 801. A
tubing string 807 is permanently deformed at 809 and 811 into recesses 803 and 805 of canister 801, respectively, to locate canister 801 with respect to tubing string 807. It should be noted that recesses 803 and 805 are merely exemplary of many various profiles that may be defined by canister 801. A packing 813 is disposed between recesses 803 and 805 of canister 801, in the annulus between tubing string 807 and canister 801. Packing 813 provides a pressure seal between the outside of tubing string 807 and the inside of canister 801. The material of packing 813 is implementation specific but may comprise a "swellable" packing material or an "injectable"
packing material. A port 815 extends through tubing string 807, packing 813, and canister 801 for communication of reservoir fluids from outside of tubing string 807 to the inside of canister 801.

[0032] Figures 9 and 10 depict stylized, schematic views, corresponding to the view of Figure 4, of two particular embodiments of canister 117. It should be noted that the embodiments of Figures 9 and 10 may be applied to other canisters of downhole array 111, such as canisters 113, 115, 119, and 801. In the embodiment of 119.0003 Figure 9, canister 117 comprises a wet compartment 901 and a dry compartment 903.
Reservoir fluid is allowed to communicate into wet compartment 901 but is inhibited from communicating into dry compartment 903. Components, such as component 905, are housed primarily in dry compartment 903, with only portions of the components that necessarily must contact the reservoir fluid extending through a bulkhead 907 into wet compartment 901 to enhance the life of such components. Dry compartment 903 further provides protection to connections between conduit 123 and component from reservoir fluids to enhance the life of such connections. Components, such as component 905, include, but are not limited to, sensors, such as temperature sensors, acoustic sensors, pressure sensors, and the like; and/or flow control devices, such as valves, regulators, nozzles, and the like. The flow control device or devices may be used, for example, in chemical injection, dewaterization, and gas lift applications.

[0033] While some components, such as component 905 are sensitive to reservoir fluids, other components, such as component 1001 of Figure 10, are not so sensitive. Accordingly, it may be advantageous in certain implementations for such components not to be protected from inadvertent contact with reservoir fluids.
Accordingly, as shown in Figure 10, canister 117 includes only wet compartment 901, omitting dry compartment 903 (shown in Figure 9).

[0034] Still referring to Figure 10, in some embodiments, reservoir fluids are inhibited from entering tubing string 121, except into wet compartment 901 or other such wet compartments, depending upon the implementation. Accordingly, an interior volume of tubing string 121 serves as a dry compartment, corresponding to dry compartment 903 (shown in Figure 9), and component 1001 is protected from inadvertent contact with reservoir fluids. Thus, for the purposes of this disclosure, the term "dry compartment" means any confined volume of downhole array 111 that lacks fluid communication with reservoir fluid.

[0035] Figure 11 depicts a perspective view of a portion of downhole array assembly 101. Canister 117 is representative of the canisters of downhole array 111, including canister 801 (shown in Figure 8). Downhole array 111 is installed inside 119.0003 tubing string 121, for example, by pumping or pulling downhole array 111 into position within tubing string 121. The position of each of the canisters, such as canister 117, is determined using a device external to tubing string 121. In one embodiment, a change in density of downhole array assembly 101 is sensed, such as with an X-ray machine, to determine the location of canister 117 in tubing string 121. In other embodiments, canister 117 includes one or more tags 1101, such as radio frequency tags or radioactive tags, which are sensed from outside tubing string 121 to determine the location of canister 117 within tubing string 121. Openings 1103 and 1105 are generated in tubing string 121 and canister 117, respectively. Canister 117 is then coupled to tubing string 121 with coupling 401, such as the embodiments shown in Figures 5-8 and described herein. Figure 11 is exemplary of a sensor array configuration of downhole array 111.

[0036] While Figures 9 and 10 depict canister 117 as including one component 901, the scope of the present invention is not so limited. Rather, one or more of the canisters, such as canisters 115 and 117, may include a plurality of components including, but not limited to, sensors, such as temperature sensors, acoustic sensors, pressure sensors, and the like; and/or flow control devices, such as valves, regulators, nozzles, and the like. In Figure 12, canisters 115 and 117 each include two such components 1201 and 1203. Note that components 1201 and 1203 may be the same type of component or different types of components.

[0037] While components 1201 and 1203 are depicted as being disposed within canisters 115 and 117, the scope of the present invention is not so limited.
Rather, as discussed herein regarding Figure 10, such components may be disposed external to a canister. Accordingly, Figure 13 depicts canisters 115 and 117 that omit dry compartments, such that a plurality of components 1301 and 1303 extend from canisters 115 and 117 into the interior of tubing string 121.

[0038] While it is advantageous to employ downhole array 111 in tubing string 121 in some implementations, the scope of the present invention includes using downhole array 111 without tubing string 121, as shown in Figure 14, for example, in 119.0003 vertical wells. Wet compartment 901 defines a port 1401 to allow communication of reservoir fluid into wet compartment 901.

[0039] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein.
Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the invention. Accordingly, the protection sought herein is as set forth in the claims below. Although the present invention is shown in a limited number of forms, it is not limited to just these forms, but is amenable to various changes and modifications.

Claims (28)

CLAIMS:

1. A downhole array, comprising:

first and second canisters;

a component disposed in each of the canisters;
a first conduit extending to the first canister; and a second conduit extending to the second canister, such that the canisters are spaced apart from one another by a predetermined distance.

2. The downhole array, according to claim 1, wherein at least one of the canisters defines a port for communication of reservoir fluid into the canister.

3. The downhole array, according to claim 2, wherein the at least one of the canisters comprises:

a wet compartment that defines the port for communication of the reservoir fluid;

a dry compartment in which the component is disposed; and a bulkhead separating the wet compartment and the dry compartment, such that the component is attached to and extends through the bulkhead to allow the reservoir fluid to contact a portion of the component.

4. The downhole array, according to claim 1, wherein the second conduit extends through the first canister to the second canister.

5. The downhole array, according to claim 1, wherein the component comprises a sensor.

6. The downhole array, according to claim 5, wherein the sensor comprises one of a temperature sensor, an acoustic sensor, and a pressure sensor.

7. The downhole array, according to claim 1, wherein the component comprises a flow control device.

8. The downhole array, according to claim 7, wherein the flow control device comprises one of a valve, a regulator, and a nozzle.

9. The downhole array, according to claim 1, further comprising a second component disposed in at least one of the canisters.

10. A downhole array assembly, comprising:
a tubing string;

first and second canisters disposed within the tubing string;

first and second couplings corresponding to the first and second canisters, each coupling attaching a corresponding one of the canisters to the tubing string;

a component disposed in each of the canisters;
a first conduit extending to the first canister; and a second conduit extending to the second canister; and wherein the canisters are spaced apart from one another by a predetermined distance.

11. The downhole array assembly, according to claim 10, wherein the tubing string is configured to allow reservoir fluid to enter an annulus between the canisters and the tubing string.

12. The downhole array assembly, according to claim 10, wherein at least one of the couplings defines a port for communication of reservoir fluid into the corresponding canister.

13. The downhole array assembly, according to claim 12, wherein the at least one of the couplings comprises a weldment joining the corresponding canister and the tubing string.

14. The downhole array assembly, according to claim 12, wherein the at least one of the couplings comprises a rivet-type fastener joining the corresponding canister and the tubing string.

15. The downhole array assembly, according to claim 10, wherein the at least one of the couplings comprises:

a plurality of recesses defined by the corresponding canister;
portions of the tubing string permanently deformed into the plurality of recesses; and a packing disposed between the plurality of recesses in an annulus between the tubing string and the corresponding canister.

16. The downhole array assembly, according to claim 12:

wherein the tubing string and the corresponding canister define threaded openings; and wherein the at least one of the couplings comprises a threaded plug threadedly engaged with the threaded openings of the tubing string and the corresponding canister.

17. The downhole array assembly, according to claim 12, wherein the at least one of the canisters comprises:

a wet compartment that defines the port for communication of the reservoir fluid;

a dry compartment in which one of the components is disposed; and a bulkhead separating the wet compartment and the dry compartment, such that the component is attached to and extends through the bulkhead to allow the reservoir fluid to contact a portion of the component.

18. The downhole array assembly, according to claim 10, wherein:
the first conduit extends to and couples a first set of canisters; and the second conduit extends to and couples a second set of canisters.

19. The downhole array assembly, according to claim 10, wherein at least one of the components comprises a sensor.

20. The downhole array assembly, according to claim 19, wherein the sensor comprises one of a temperature sensor, an acoustic sensor, and a pressure sensor.

21. The downhole array assembly, according to claim 10, wherein at least one of the components comprises a flow control device.

22. The downhole array assembly, according to claim 21, wherein the flow control device comprises one of a valve, a regulator, and a nozzle.

23. The downhole array, according to claim 10, further comprising a second component disposed in at least one of the canisters.

24. A well, comprising:
a wellhead;

a borehole extending from the wellhead into a productive interval;
a tubing string disposed in the borehole and extending from the wellhead into the productive interval;

first and second canisters disposed within the tubing string;

first and second couplings corresponding to the first and second canisters, each of the couplings attaching a corresponding canister to the tubing string;

a component disposed in each of the canisters;

a first conduit extending from the wellhead to the first canister; and a second conduit extending from the wellhead to the second canister; and wherein the canisters are spaced apart from one another by a predetermined distance.

25. The well, according to claim 24, wherein the tubing string is configured to allow reservoir fluid to enter an annulus between the canisters and the tubing string.

26. The well, according to claim 24, wherein at least one of the couplings defines a port for communication of reservoir fluid into the corresponding canister.

27. The well, according to claim 26, wherein at least one of the canisters comprises:

a wet compartment that defines the port for communication of the reservoir fluid;

a dry compartment in which the component is disposed; and a bulkhead separating the wet compartment and the dry compartment, such that the component is attached to and extends through the bulkhead to allow the reservoir fluid to contact a portion of the component.

28. The well, according to claim 24, wherein at least one conduit is operable to retrieve fluids from the productive interval of the well.