EP2749733A2 - Downhole probe assembly - Google Patents
Downhole probe assembly Download PDFInfo
- Publication number
- EP2749733A2 EP2749733A2 EP14161780.3A EP14161780A EP2749733A2 EP 2749733 A2 EP2749733 A2 EP 2749733A2 EP 14161780 A EP14161780 A EP 14161780A EP 2749733 A2 EP2749733 A2 EP 2749733A2
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- EP
- European Patent Office
- Prior art keywords
- piston
- draw down
- fluid
- formation
- assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B49/00—Testing the nature of borehole walls; Formation testing; Methods or apparatus for obtaining samples of soil or well fluids, specially adapted to earth drilling or wells
- E21B49/08—Obtaining fluid samples or testing fluids, in boreholes or wells
- E21B49/10—Obtaining fluid samples or testing fluids, in boreholes or wells using side-wall fluid samplers or testers
Definitions
- ancillary operations such as monitoring the operability of equipment used during the drilling process or evaluating the production capabilities of formations intersected by the wellbore. For example, after a well or well interval has been drilled, zones of interest are often tested to determine various formation properties such as permeability, fluid type, fluid quality, formation temperature, formation pressure, bubblepoint and formation pressure gradient. These tests are performed in order to determine whether commercial exploitation of the intersected formations is viable and how to optimize production.
- Wireline formation testers and drill stem testing (DST) have been commonly used to perform these tests.
- the basic DST test tool consists of a packer or packers, valves or ports that may be opened and closed from the surface, and two or more pressure-recording devices. The tool is lowered on a work string to the zone to be tested. The packer or packers are set, and drilling fluid is evacuated to isolate the zone from the drilling fluid column. The valves or ports are then opened to allow flow from the formation to the tool for testing while the recorders chart static pressures. A sampling chamber traps clean formation fluids at the end of the test.
- WFTs generally employ the same testing techniques but use a wireline to lower the test tool into the well bore after the drill string has been retrieved from the well bore, although WFT technology is sometimes deployed on a pipe string.
- the wireline tool typically uses packers also, although the packers are placed closer together, compared to drill pipe conveyed testers, for more efficient formation testing. In some cases, packers are not used. In those instances, the testing tool is brought into contact with the intersected formation and testing is done without zonal isolation across the axial span of the circumference of the borehole wall.
- WFTs may also include a probe assembly for engaging the borehole wall and acquiring formation fluid samples.
- the probe assembly may include an isolation pad to engage the borehole wall. The isolation pad seals against the formation and around a hollow probe, which places an internal cavity in fluid communication with the formation. This creates a fluid pathway that allows formation fluid to flow between the formation and the formation tester while isolated from the borehole fluid.
- the probe In order to acquire a useful sample, the probe must stay isolated from the relative high pressure of the borehole fluid. Therefore, the integrity of the seal that is formed by the isolation pad is critical to the performance of the tool. If the borehole fluid is allowed to leak into the collected formation fluids, a non-representative sample will be obtained and the test will have to be repeated.
- the drill string with the drill bit must be retracted from the borehole. Then, a separate work string containing the testing equipment, or, with WFTs, the wireline tool string, must be lowered into the well to conduct secondary operations. Interrupting the drilling process to perform formation testing can add significant amounts of time to a drilling program.
- DSTs and WFTs may also cause tool sticking or formation damage. There may also be difficulties of running WFTs in highly deviated and extended reach wells. WFTs also do not have flowbores for the flow of drilling mud, nor are they designed to withstand drilling loads such as torque and weight on bit.
- the formation pressure measurement accuracy of drill stem tests and, especially, of wireline formation tests may be affected by filtrate invasion and mudcake buildup because significant amounts of time may have passed before a DST or WFT engages the formation.
- Mud filtrate invasion occurs when the drilling mud fluids displace formation fluids. Because the mud filtrate ingress into the formation begins at the borehole surface, it is most prevalent there and generally decreases further into the formation. When filtrate invasion occurs, it may become impossible to obtain a representative sample of formation fluids or, at a minimum, the duration of the sampling period must be increased to first remove the drilling fluid and then obtain a representative sample of formation fluids.
- the mudcake is made up of the solid particles that are deposited on the side of the well as the filtrate invades the near well bore during drilling.
- the prevalence of the mudcake at the borehole surface creates a "skin.”
- the mudcake also acts as a region of reduced permeability adjacent to the borehole.
- Another testing apparatus is the measurement while drilling (MWD) or logging while drilling (LWD) tester.
- Typical LWD/MWD formation testing equipment is suitable for integration with a drill string during drilling operations.
- Various devices or systems are provided for isolating a formation from the remainder of the wellbore, drawing fluid from the formation, and measuring physical properties of the fluid and the formation.
- LWD/MWD testers the testing equipment is subject to harsh conditions in the wellbore during the drilling process that can damage and degrade the formation testing equipment before and during the testing process. These harsh conditions include vibration and torque from the drill bit, exposure to drilling mud, drilled cuttings, and formation fluids, hydraulic forces of the circulating drilling mud, and scraping of the formation testing equipment against the sides of the wellbore.
- Sensitive electronics and sensors must be robust enough to withstand the pressures and temperatures, and especially the extreme vibration and shock conditions of the drilling environment, yet maintain accuracy, repeatability, and reliability.
- the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to".
- the terms “couple,” “couples”, and “coupled” used to describe any electrical connections are each intended to mean and refer to either an indirect or a direct electrical connection.
- that interconnection may be through an electrical conductor directly interconnecting the two devices, or through an indirect electrical connection via other devices, conductors and connections.
- hydrocarbons are stored in subterranean formations. Hydrocarbons are not typically located in large underground pools, but are instead found within very small holes, or pore spaces, within certain types of rock. Therefore, it is critical to know certain properties of both the formation and the fluid contained therein.
- certain formation and formation fluid properties will be referred to in a general sense. Such formation properties include, but are not limited to: pressure, permeability, viscosity, mobility, spherical mobility, porosity, saturation, coupled compressibility porosity, skin damage, and anisotropy.
- formation fluid properties include, but are not limited to: viscosity, compressibility, flowline fluid compressibility, density, resistivity, composition and bubble point.
- Permeability is the ability of a rock formation to allow hydrocarbons to move between its pores, and consequently into a wellbore.
- Fluid viscosity is a measure of the ability of the hydrocarbons to flow, and the permeability divided by the viscosity is termed "mobility.”
- Porosity is the ratio of void space to the bulk volume of rock formation containing that void space.
- Saturation is the fraction or percentage of the pore volume occupied by a specific fluid (e.g., oil, gas, water, etc.).
- Skin damage is an indication of how the mud filtrate or mud cake has changed the permeability near the wellbore.
- Anisotropy is the ratio of the vertical and horizontal permeabilities of the formation.
- Resistivity of a fluid is the property of the fluid which resists the flow of electrical current. Bubble point occurs when a fluid's pressure is brought down at such a rapid rate, and to a low enough pressure, that the fluid, or portions thereof, changes phase to a gas. The dissolved gases in the fluid are brought out of the fluid so gas is present in the fluid in an undissolved state. Typically, this kind of phase change in the formation hydrocarbons being tested and measured is undesirable, unless the bubblepoint test is being administered to determine what the bubblepoint pressure is.
- a formation tester tool 10 is shown as a part of bottom hole assembly 6 which includes an MWD sub 13 and a drill bit 7 at its lower most end.
- Bottom hole assembly 6 is lowered from a drilling platform 2, such as a ship or other conventional platform, via drill string 5.
- Drill string 5 is disposed through riser 3 and well head 4.
- Conventional drilling equipment (not shown) is supported within derrick 1 and rotates drill string 5 and drill bit 7, causing bit 7 to form a borehole 8 through the formation material 9.
- the borehole 8 penetrates subterranean zones or reservoirs, such as reservoir 11, that are believed to contain hydrocarbons in a commercially viable quantity.
- formation tester 10 may be employed in other bottom hole assemblies and with other drilling apparatus in land-based drilling, as well as offshore drilling as shown in Figure 1 .
- the bottom hole assembly 6 contains various conventional apparatus and systems, such as a down hole drill motor, rotary steerable tool, mud pulse telemetry system, measurement-while-drilling sensors and systems, and others well known in the art.
- Figure 2A illustrates the electronics module 20, which may include battery packs, various circuit boards, capacitors banks and other electrical components.
- Figure 2B shows fillport assembly 22 having fillports 24, 26 for adding or removing hydraulic or other fluids to the tool 10.
- Below fillport assembly 22 is hydraulic insert assembly 30.
- Below assembly 30 is the hydraulic connectors ring assembly 32, which acts as a hydraulic line manifold.
- Figure 2C illustrates the portion of tool 10 including equalizer valve 60, formation probe assembly 50 (or probe assembly 200), draw down shutoff valve assembly 74, draw down piston assemblies 70, 72 and stabilizer 36.
- pressure instrument assembly 38 including the pressure transducers used by formation probe assemblies 50, 200.
- Equalizer valve 60 may be any of a variety of equalizer valves known to one skilled in the art.
- formation probe assembly 50 is disposed within probe drill collar 12, and covered by probe cover plate 51. Also disposed within probe collar 12 is an equalizer valve 60 having a valve cover plate 61. Adjacent formation probe assembly 50 and equalizer valve 60 is a flat 136 in the surface 17 of probe collar 12. Probe drill collar 12 includes a draw down cover 76 for protecting other devices associated with the formation probe assembly 50 mounted in the collar 12, such as draw down pistons (not shown).
- Formation probe assembly 50 and equalizer valve 60 are positioned in probe collar 12. Formation probe assembly 50 and equalizer valve 60 are mounted in probe collar 12 just above the flowbore 14. Flowbore 14 may be deviated from the center longitudinal axis 12a of probe collar 12, or from other portions 14b, 14c of flowbore 14, to accommodate at least formation probe assembly 50. For example, in Figure 5 , flowbore portion 14a is offset radially from the longitudinal axis 12a, and also from the flowbore portion 14b via transition flowbore portion 14c. Also shown are draw down piston assemblies 70, 72 and draw down shutoff valve 74.
- Formation probe assembly 50 is retained in probe collar 12 by threaded engagement with collar 12 and also by cover plate 51.
- Formation probe assembly 50 generally includes stem 92, a generally cylindrical threaded adapter sleeve 94, piston 96 adapted to reciprocate within adapter sleeve 94, and a snorkel assembly 98 adapted for reciprocal movement within piston 96.
- Probe collar 12 includes an aperture 90 for receiving formation probe assembly 50.
- Cover plate 51 fits over the top of formation probe assembly 50 and retains and protects formation probe assembly 50 when the formation probe assembly 50 is within probe collar 12. Formation probe assembly 50 may extend and retract through aperture 52 in cover plate 51.
- Stem 92 includes a circular base portion 105 with an outer flange 106 having stem holding screw 97 (shown in Figure 6B ) for retaining stem 92 in aperture 90.
- Extending from base 105 is a tubular extension 107 having central passageway 108.
- the end of extension 107 includes internal threads at 109.
- Central passageway 108 is in fluid connection with fluid passageway 91 (not shown, but seen schematically in Figure 9 ) that connects to fluid passageway 93 (not shown, but seen schematically in Figure 9 ) leading to other portions of tool 10, including equalizer valve 60.
- Adapter sleeve 94 includes inner end 111 that engages flange 106 of stem 92. Adapter sleeve 94 is secured within aperture 90 by threaded engagement with collar 12 at segment 110. The outer end 112 of adapter sleeve 94 may extend to be substantially flushed with recess 55 formed in collar 12 for receiving cover plate 51. Outer end 112 also includes flange 158 for engaging recess 162 of cover plate 51.
- Adapter sleeve 94 includes cylindrical inner surface 113 having reduced diameter portions 114, 115. A seal 116 is disposed in surface 114.
- Piston 96 is slidingly retained within adapter sleeve 94 and generally includes cylindrical outer surface 141 having an increased diameter base portion 118. A seal 143 is disposed in increased diameter portion 118. Just below base portion 118, piston 96 may rest on flange 106 of stem base portion 105 while formation probe assembly 50 is in the fully retracted position as shown in Figure 6A . Piston 96 may also include cylindrical inner surface 145 having reduced diameter portion 147. Piston 96 may further include central bore 121 having a bore surface 120 and extending through upper extending portion 119.
- seal pad 180 At the top of extending portion 119 of piston 96 is a seal pad 180.
- Seal pad 180 may be donut-shaped with a curved outer sealing surface 183 and central aperture 186.
- seal pad 180 may include numerous other geometries as is known in the art, or, for example, as is seen in U.S. Patent Application No. 10/440,835 entitled “MWD Formation Tester.”
- Base surface 185 of seal pad 180 may be coupled to a skirt 182.
- Seal pad 180 may be bonded to skirt 182, or otherwise coupled to skirt 182, such as by molding seal pad 180 onto skirt 182 such that the seal pad material fills grooves or holes in skirt 182, as can be seen in U.S. Patent Application No. 10/440,835 .
- Skirt 182 is detachably coupled to extending portion 119 by way of threaded engagement with surface 120 of central bore 121 (see Figure 6A ), or other means of engagement, such as a pressure fit with central bore surface 120. Because the seal pad/skirt combination may be detachable from extending portion 119, it is easily replaced in the field. Alternatively, seal pad 180 may be coupled directly to extending portion 119 without using a skirt.
- Seal pad 180 is preferably made of an elastomeric material. Seal pad 180 seals and prevents drilling fluid or other contaminants from entering the formation probe assembly 50 during formation testing. More specifically, seal pad 180 may seal against the filter cake that may form on a borehole wall. Typically, the pressure of the formation fluid is less than the pressure of the drilling fluids that are injected into the borehole. A layer of residue from the drilling fluid forms a filter cake on the borehole wall and separates the two pressure areas. Seal pad 180, when extended, may conform its shape to the borehole wall and/or mud cake and forms a seal through which formation fluids can be collected and/or formation properties measured.
- the seal pad 180 may have an internal cavity such that it can retain a volume of fluid.
- a fluid may be pumped into the seal pad cavity at variable rates such that the pressure in the seal pad cavity may be increased and decreased.
- Fluids used to fill the seal pad may include hydraulic fluid, saline solution or silicone gel.
- the seal pad may be emptied or unpressured as the probe extends to engage the borehole wall.
- the seal pad may be pressured by filling the seal pad with fluid, thereby conforming the seal pad surface to the contour of the borehole wall and providing a better seal.
- the seal pad may be filled, either before or after engagement with the borehole wall, with an electro-rheological fluid.
- An electro-rheological fluid may be an insulating oil containing a dispersion of fine solid particles, for example, 5 ⁇ m to 50 ⁇ m in diameter.
- Such an electro-rheological fluid is well known in the art. When subjected to an electric field, theses fluids develop an increased shear stress and an increased static yield stress that make them more resistant to flow. This change of fluid properties is evident, for example, as an increase in viscosity, most notably the plastic viscosity, when the electric field is applied. The fluid in the seal pad may effectively become semi-solid.
- the semi-solid effect is reversed when the fluid is no longer subjected to the electric field.
- the electro-rheological fluid that may fill the seal pad becomes less viscous, causing the seal pad to conform to the contour of a borehole wall.
- an electric field may be applied to the electro-rheological fluid inside the seal pad, causing an increase in fluid viscosity, a stiffening of the seal pad, and a better seal.
- snorkel assembly 98 includes a base portion 125, a snorkel extension 126, and a central passageway 127 extending through base 125 and extension 126.
- Base portion 125 may include a cylindrical outer surface 122 and inner surface 124.
- Extension 126 may include a cylindrical outer surface 128 and inner surface 138.
- Disposed inside the top of extension 126 is a screen 100.
- Screen 100 is a generally tubular member having a central bore 132 extending between a fluid inlet end 131 and fluid outlet end 135.
- Screen 100 further includes a flange 130 adjacent to fluid inlet end 131 and an internally slotted segment 133 having slots 134. Between slotted segment 133 and outlet end 135, screen 100 includes threaded segment 137 for threadedly engaging snorkel extension 126.
- scraper tube keeper 152 Threaded to the bottom of base portion 125 of snorkel 98 is scraper tube keeper 152 having a circular base portion 154 with flange 153, a tubular extension 156 having a central passageway 155 and a central aperture 157 for receiving stem extension 107.
- retainer ring 159 Just below scraper tube keeper 152 is retainer ring 159, which provides seated engagement with snorkel 98 such that the movement of snorkel 98 is limited in the retract direction.
- Scraper tube keeper 152 supports scraper tube 150 when scraper tube 150 is in the retracted position shown in Figure 6B .
- Scraper tube 150 having central passageway 151 extends up from scraper tube keeper 152 and through passageway 127 of snorkel 98. Coupled at the top of scraper tube 150 is scraper or wiper 160.
- Scraper 160 is threadedly engaged with scraper tube 150 at threaded segment 161.
- Scraper 160 is a generally cylindrical member including scraper plug portion 163, central bore 164 and apertures 166 that are in fluid communication with central bore 164.
- Scraper 160 is disposed within central bore 132 of screen 100 and may be actuated back and forth (or reciprocal) between screen inlet end 131 and outlet end 135.
- apertures 166 are in fluid communication with fluid outlet end 135 of screen 100, thereby allowing fluid to pass from screen 100, through scraper bore 164, and into central passageway 155 of scraper tube 150.
- Scraper or wiper 160 is thus configured to be a moveable or floating scraper.
- the actuation of scraper 160 may be a rotational movement around the longitudinal axis of scraper 160. This rotational movement may be in place of the reciprocal movement, or in addition to the reciprocal movement.
- a connector 176 is disposed in aperture 178 of probe collar 12, just beneath inner end 111 of sleeve 94.
- Contact lead 175 electrically connects connector 176, via a wire, to a contact assembly (not shown) preferably disposed in flange 106 of stem base portion 105 so that the contact assembly can be in direct contact with base portion 118 of piston 96.
- Figures 8A-8B show the details of connector 176 and contact assembly 310, with the surrounding structures shown in a more general fashion such that the different parts of formation probe assembly 50a generally correspond with similar parts of formation probe assembly 50 of Figures 6A-6B .
- connector 176a is disposed in aperture 178a in probe collar 12a.
- Contact lead 175a is coupled to wire 300, which extends through recess 301 in collar 12a to opening 305 in base portion 105a of stem 92a. From opening 305, wire 300 extends through base portion 105a to a cavity 307, where contact assembly 310 is disposed.
- Contact assembly 310 generally includes housing 316 having aperture 317, a conductive contact body 312 having a flange 314 and a central bore 319, a stripped end 318 of wire 300 extending into and soldered to bore 319, a non-conductive spring support 322, and wave springs 324.
- the flange 314 of body 312 is disposed between the upper portion of housing 316 and the lower portion of spring support 322. Disposed between spring support 322 and flange 314 are wave springs 324, which are supported by lower plate 326 and upper plate 328.
- Springs 324 provide an upward force on flange 314 such that top surface 313 of body 312 extends out of aperture 317 such that top surface 313 protrudes out of cavity 307.
- piston 96a comes into contact with and presses downward on surface 313 of body 312, causing springs 324 to compress and bottom surface 315 to move downward into space 324.
- an electric circuit is completed to ground (not shown) through piston 96a, providing a signal to the tool electronics (not shown) that formation probe assembly 50a has been fully retracted.
- piston 96a continues to travel until making contact with base portion 105a of stem 92a. Heat shrink 320 is shrunk in place over wire 300 for mechanical protection.
- formation probe assembly 50 is assembled such that piston base 118 is permitted to reciprocate along surface 113 of adapter sleeve 94, and piston outer surface 141 is permitted to reciprocate along surface 114.
- snorkel base 125 is disposed within piston 96 and is adapted for reciprocal movement along surface 147 while flange 153 of scraper tube keeper 152 reciprocates along surface 145.
- Snorkel extension 126 is adapted for reciprocal movement along piston surface 120.
- Central passageway 127 of snorkel 98 is axially aligned with tubular extension 107 of stem 92, scraper tube keeper 152, scraper tube 150, scraper 160 and with screen 100.
- Formation probe assembly 50 is reciprocal between a fully retracted position, as shown in Figure 6A , and a fully extended position, as shown in Figure 6B .
- scraper tube 150 is reciprocal between a fully retracted position, as shown in Figures 6A-6B , and a fully extended position, as is illustrated by a similar scraper tube 278 in Figures 7A-7E .
- fluid may be communicated between central passageway 108 of extension 107, passageway 155 of scraper tube keeper 152, passageway 151 of scraper tube 150, scraper bore 164, scraper apertures 166, screen 100, and the surrounding environment 15.
- Formation probe assembly 50 is normally in the retracted position. Formation probe assembly 50 remains retracted when not in use, such as when the drill string is rotating while drilling if formation probe assembly 50 is used for an MWD application, or when the wireline testing tool is being lowered into borehole 8 if formation probe assembly 50 is used for a wireline testing application.
- Figure 6A shows formation probe assembly 50 in the fully retracted position, except that scraper tube 150 is shown in the retracted position, and scraper tube 150 is typically extended when formation probe assembly 50 is in this position, as shown in Figures 7A-7E .
- Figures 7A-7F will be referred to in describing the operation of formation probe assembly 50 because the structures of formation probe assembly 50 previously described are similar to corresponding parts of probe assembly 200 seen in Figures 7A-7F .
- Formation probe assembly 50 typically begins in the retracted position, as shown in Figure 6A .
- a force is applied to base portion 118 of piston 96, preferably by using hydraulic fluid.
- Piston 96 extends relative to the other portions of formation probe assembly 50 until retainer ring 159 engages flange 153 of scraper tube keeper 152.
- This position of piston 96 relative to snorkel assembly 98 can be seen in Figure 7B .
- piston 96 and snorkel assembly 98 continue to move upward together.
- Base portion 118 slides along adapter sleeve surface 113 until base portion 118 comes into contact with shoulder 170.
- formation probe assembly 50 will continue to pressurize reservoir 54 until reservoir 54 reaches a certain pressure P 1 .
- formation probe assembly 50 will continue to apply pressure to seal pad 180 by pressurizing reservoir 54 up to the pressure P 1 .
- the pressure P 1 applied to formation probe assembly 50 may be 1,200 p.s.i.
- snorkel assembly 98 The continued force from the hydraulic fluid in reservoir 54 causes snorkel assembly 98 to extend such that the outer end of snorkel extension 126, inlet end 131 of screen 100 and the top of scraper 160 extend beyond seal pad surface 183 through seal pad aperture 186.
- This snorkel extending force must overcome the retract force being applied on the retract side of snorkel base portion 125 facing piston shoulder 172.
- the retract force provided by retract accumulator 424 and the retract valves, was greater than the extend force, thereby maintaining snorkel 98 in the retract position.
- the extend force continues to increase until it overcomes the retract force at, for example, 900 p.s.i.
- Snorkel assembly 98 stops extending outward when snorkel base portion 125 comes into contact with shoulder 172 of piston 96.
- Scraper tube 150 and scraper 160 are still in the extended position, as is best shown with the snorkel assembly and piston configuration of Figure 7E .
- snorkel assembly 98 comes into contact with a borehole wall before snorkel base portion 125 comes into contact with shoulder 172 of piston 96, continued force from the hydraulic fluid pressure in reservoir 54 is applied up to the previously mentioned maximum pressure.
- the maximum pressure applied to snorkel assembly 98 may be 1,200 p.s.i.
- the snorkel and seal pad will contact the borehole wall before either piston 96 or snorkel 98 shoulders at full extension. Then, the force applied on the seal pad is reacted by stabilizer 36, or other similar device disposed on or near probe collar 12.
- seal pad 180 should seal against the mudcake on borehole wall 16 through a combination of pressure and seal pad extrusion.
- the seal separates snorkel assembly 98 from the mudcake, drilling fluids and other contaminants outside of seal pad 180.
- snorkel extension 126, screen inlet end 131 and the top of scraper 160 pierce the mudcake that has been sealed off, and preferably go through the entire mudcake layer and into formation 9.
- the piston 96 and snorkel 98 assembly configuration looks similar to the piston and snorkel configuration shown in Figure 7E . While extending snorkel extension 126 into the mudcake and formation, contaminants and debris tend to gather on screen 100 which can affect the sampling of formation fluids. To clear the debris, which may be mudcake or other contaminants from previous sampling procedures, scraper 160 may be retracted after snorkel assembly 98 has been extended. A downward retract force is applied to scraper tube 150, preferably by applying a hydraulic fluid force downward on flange 177 of scraper tube 150. The cavity formed by scraper tube 150 and snorkel surface 124 fills with hydraulic fluid as scraper tube 150 moves downward, until scraper tube 150 bottoms out on scraper tube keeper 152.
- scraper 160 As scraper 160 is drawn within snorkel extension 126 during this process, scraper 160 passes through screen 100 while also frictionally engaging screen 100, thereby agitating and removing debris that has gathered on screen 100.
- debris agitation may be achieved with rotational movement of scraper 160 about its longitudinal axis within screen 100.
- apertures 166 When scraper tube 150 is fully retracted, apertures 166 radially align with outlet end 135 of screen 100 such that fluid communication is possible between bore 132 of screen 100 and passageway 151 of scraper tube 150. This scraper 160 action that removes debris is preferably performed as part of the formation probe assembly 50 retract sequence, as described below.
- forces may be applied to snorkel 98 and piston 96 in opposite directions relative to the extending forces. Simultaneously, the extending forces may be reduced or ceased to aid in probe retraction.
- a hydraulic force is applied to snorkel base portion 125 at shoulder 172 to push snorkel assembly 98 down until flange 153 of scraper tube keeper 152 sits on retainer ring 159, thereby fully retracting snorkel assembly 98.
- a hydraulic force is applied downward on piston base portion 118 at shoulder 170 until base portion 118 bottoms out on stem base portion 105, thereby fully retracting formation probe assembly 50.
- probe retract switch 176 When piston 96 contacts stem base portion 105, probe retract switch 176 is triggered as described above, signaling a successful retraction of formation probe assembly 50.
- Scraper 160 may be extended to its original position at any time during retraction. When the extend pressure on the probe assembly, which provides the retract pressure for the scraper assembly because the probe assembly extend portions are hydraulically coupled to the scraper assembly retract portions, falls below the extend pressure on the scraper assembly, scraper 160 is extended.
- Probe collar 202 having flowbore 14a houses telescoping formation probe assembly 200.
- Probe assembly 200 extends to reach a borehole wall that is further displaced from collar 202.
- Such borehole walls that may be displaced further from collar 12 may be found in washed out portions of a well, irregular holes in the well, wells drilled with hole openers or near bit reamers or large wells drilled with bi-center bits.
- Telescoping probe assembly 200 is useful in reaching a borehole wall in these types of wells.
- Telescoping probe assembly 200 generally includes stem plate 210, stem 212, a generally cylindrical threaded adapter sleeve 220, an outer piston 230 adapted to reciprocate within adapter sleeve 220, a piston 240 adapted to reciprocate within outer piston 230, and a snorkel assembly 260 adapted for reciprocal movement within piston 240.
- Probe collar 202 includes an aperture 204 for receiving telescoping formation probe assembly 200.
- Cover plate 206 fits over the top of probe assembly 200 and retains and protects assembly 200 within probe collar 202.
- Formation probe assembly 200 is configured to extend through aperture 208 in cover plate 206.
- adapter sleeve 220 includes inner end 221 near the bottom 207 of aperture 204.
- Adapter sleeve 220 is secured within aperture 204 by threaded engagement with collar 202 at segment 209.
- the outer end 223 of adapter sleeve 220 extends to be substantially flushed with opening 205 of aperture 204 formed in collar 202.
- Outer end 223 includes flanges 225 for engaging cover plate 206.
- Adapter sleeve 220 includes cylindrical inner surface 227 having reduced diameter portion 226.
- a seal 229 is disposed in surface 226.
- stem plate 210 includes a circular base portion 213 with an outer flange 214. Extending from base 213 is a short extension 216. Extending through extension 216 and base 213 is a central passageway 218 for receiving the lower end 215 of stem 212 having central passageway 203. Lower end 215 threadedly engages stem plate passageway 218. Central passageway 218 is in fluid connection with fluid passageway 91 (not shown, but seen schematically in Figure 9 ) that connects to fluid passageway 93 (not shown, but seen schematically in Figure 9 ) leading to other portions of tool 10, including equalizer valve 60.
- Stem 212 extends up through the center of probe assembly 200. Disposed about stem 212 is outer stem 219. Threadedly engaged at the top of outer stem 219 is outer stem capture screw 222 having central bore 224.
- outer piston 230 is slidingly retained within adapter sleeve 220 and generally includes cylindrical outer surface 232 having an increased diameter base portion 234. A seal 235 is disposed in increased diameter portion 234. Outer piston 230 also includes cylindrical inner surface 236 having reduced diameter portions 237, 238 at upper extending portion 233. A seal 239 is disposed in surface 237.
- piston 240 is slidingly retained within outer piston 230 and generally includes cylindrical outer surface 242 having an increased diameter base portion 244.
- a seal 245 is disposed in increased diameter portion 244.
- piston 240 rests on capture sleeve 254 which is engaged with base portion 234 of outer piston 230.
- Retainer ring 256 is engaged at the bottom of capture sleeve 254 and holds the capture sleeve in position.
- Piston 240 also includes cylindrical inner surface 246 having reduced diameter portion 248.
- Piston 240 further includes central bore 249 having bore surface 241 and extending through upper extending portion 250.
- seal pad 280 At the top of extending portion 250 of piston 240 is a seal pad 280.
- seal pad 280 may be donut-shaped with a curved outer surface 283 and central aperture 286.
- seal pad 280 may include numerous other geometries as is known in the art, or, for example, as is seen in U.S. Patent Application No. 10/440,835 entitled "MWD Formation Tester.”
- Base surface 285 of seal pad 280 may be coupled to a skirt 282.
- Seal pad 280 may be bonded to skirt 282, or otherwise coupled to skirt 282, such as by molding seal pad 280 onto skirt 282 such that the seal pad material fills grooves or holes in skirt 282, as can be seen in U.S. Patent Application No.
- Skirt 282 is detachably coupled to extending portion 250 by way of threaded engagement with surface 241 of central bore 249, or other means of engagement, such as a pressure fit with central bore surface 241. Because the seal pad/skirt combination is detachable from extending portion 250, it is easily replaced in the field. Alternatively, seal pad 280 may be coupled directly to extending portion 250 without using a skirt. Other characteristics of seal pad 280, such as seal pad material and the way seal pad 280 functions, are similar to the previously described seal pad 180.
- snorkel 260 includes a base portion 262, a snorkel extension 266, and a central passageway 264 extending through base 262 and extension 266.
- Base portion 262 includes a cylindrical outer surface 268 and inner surface 269.
- Extension 266 includes a cylindrical outer surface 263 and inner surface 265.
- Screen 290 Disposed inside the top of extension 266 is a screen 290, best shown in Figure 7F .
- Screen 290 is a generally tubular member having a central bore 292 extending between a fluid inlet end 294 and fluid outlet end 296.
- Screen 290 further includes a flange 298 adjacent to fluid inlet end 294 and an internally slotted segment 293 having slots 295. Between slotted segment 293 and outlet end 296, screen 290 includes threaded segment 297 for threadedly engaging snorkel extension 266.
- scraper tube keeper 270 Threaded to the bottom of base portion 262 of snorkel 260 is scraper tube keeper 270 having a circular base portion 272 and retaining edge 273, a tubular extension 274 having a central passageway 275 and a central aperture 271 for receiving outer stem 219.
- Outer stem 219 includes central passageway 243.
- a retainer ring 277 is radially aligned and engageable with retaining edge 273, which limits the movement of snorkel 260 in the retract direction. After snorkel 260 has been extended, retainer ring 277 is disposed below scraper tube keeper 270 in piston surface 246, as can be seen in Figure 7E .
- Scraper tube keeper 270 supports scraper tube 278 when scraper tube 278 is in the retracted position shown in Figure 7F , and isolates the hydraulic fluid reservoir formed by tubular extension 274 and snorkel surface 269.
- Scraper tube 278 having central passageway 279 is slidingly retained above scraper tube keeper 270 in passageway 264 of snorkel 260.
- Scraper 288 is coupled at the top of scraper tube 278.
- Scraper 288 is threadedly engaged with scraper tube 278 at threaded segment 281.
- Scraper 288 is a generally cylindrical member including scraper plug portion 284, central bore 287 and apertures 289 that are in fluid communication with central bore 287.
- Scraper 288 is disposed within central bore 292 of screen 290 and is reciprocal between screen inlet end 294 and outlet end 296; alternatively, as previously described, scraper 288 may be rotatable within screen 290.
- apertures 289 are in fluid communication with fluid outlet end 296 of screen 290, thereby allowing fluid to pass from screen 290, through scraper bore 287, and into central passageway 279 of scraper tube 278.
- a probe retract switch connector 276 is disposed in aperture 278 of probe collar 202, just beneath inner end 221 of sleeve 220.
- the details of switch connector 276 are similar to the previously described switch 176, above, with reference to figures 8A-8B .
- switch and connector 276 are electrically coupled to a contact assembly disposed in stem base portion 213. The contact assembly contacts piston 240 when piston 240 is bottomed out on stem base portion 213 indicating to the tool electronics that probe assembly 200 is fully retracted.
- Formation probe assembly 200 is assembled such that outer piston base 234 is permitted to reciprocate along surface 227 of adapter sleeve 220, and outer piston surface 232 is permitted to reciprocate along surface 226. Similarly, piston base portion 244 is permitted to reciprocate along outer piston inner surface 236, and piston surface 242 is permitted to reciprocate along outer piston surface 237.
- Snorkel base portion 262 is disposed within piston 240 and is adapted for reciprocal movement along surface 248 while retaining edge 273 of scraper tube keeper 270 reciprocates between retainer ring 277 and decreased diameter portion 248.
- Snorkel extension 266 is adapted for reciprocal movement along piston surface 241.
- Central passageway 264 of snorkel 260 is axially aligned with stem 212, outer stem 219, scraper tube keeper 270, scraper tube 278, scraper 288 and with screen 290.
- Formation probe assembly 200 is reciprocal between a fully retracted position, as shown in Figure 7A , and a fully extended position, as shown in Figure 7F .
- scraper tube 278 is reciprocal between a fully extended position, as shown in Figures 7A-7E , and a fully retracted position, as is illustrated in Figure 7F .
- scraper tube 278 When scraper tube 278 is fully retracted, fluid may be communicated between central passageway 203 of stem 212, passageway 243 of outer stem 219, passageway 275 of scraper tube keeper 270, passageway 279 of scraper tube 278, bore 287 of scraper 288, scraper apertures 289, screen 290, and the surrounding environment 15.
- Formation probe assembly 200 typically begins in the retracted position, as shown in Figure 7A .
- Assembly 200 remains retracted when not in use, such as when the drill string is rotating while drilling if assembly 200 is used for an MWD application, or when the wireline testing tool is being lowered into borehole 8 if assembly 200 is used for a wireline testing application.
- Figure 7A shows assembly 200 in the fully retracted position, with scraper tube 278 in the extended position.
- a force is applied to base portion 234 of outer piston 230, preferably by using hydraulic fluid.
- Outer piston 230 raises relative to adapter sleeve 220, with outer piston base portion sliding along sleeve surface 227.
- Retainer ring 256 and capture sleeve 254 force piston 240 upward along with outer piston 230 by pressing on piston base portion 244.
- snorkel 260 remains seated on stem plate 210 while outer piston 230 and piston 240 begin to rise, until retainer ring 277 contacts retaining edge 273 of scraper tube keeper 270.
- fluid reservoir 334 enlarges and fills until outer piston base portion 234 seats on adapter sleeve shoulder 332, as shown in Figure 7C .
- hydraulic fluid is directed into reservoir 336, causing piston 240 and snorkel 260 to extend out, with piston base portion 244 sliding along outer piston surface 236.
- piston base portion 244 seats on outer piston shoulder 342, as shown in Figure 7D .
- snorkel 260 and seal pad 280 ( Figure 7C ) contact the borehole wall prior to reaching full extension, as previously described. The tool stabilizer, or other such device, will react the probe extension force.
- seal pad 280 is preferably engaged with the borehole wall (not shown).
- probe assembly 200 will continue to pressurize the reservoirs 334, 336 until the reservoirs reach a maximum pressure.
- probe assembly 200 will continue to apply pressure to seal pad 280 up to the previously mentioned maximum pressure.
- the maximum pressure applied by probe assembly 200 may be 1,200 p.s.i.
- snorkel 260 slides along surfaces 248, 241 as hydraulic fluid is directed into reservoir 338 and this snorkel extend force increases.
- This snorkel extending force must overcome the retract force being applied on the retract side of snorkel base portion 262 facing piston shoulder 352.
- the retract force provided by retract accumulator 424 and the retract valves, was greater than the extend force, thereby maintaining snorkel 260 in the retract position.
- the extend force continues to increase until it overcomes the retract force at, for example, 900 p.s.i. Snorkel base portion 262 finally seats on piston shoulder 352, as shown in Figure 7E .
- Snorkel 260 has extended such that the outer end of snorkel extension 266, inlet end 294 of screen 290 and the top of scraper 288 extend beyond seal pad surface 283 through seal pad aperture 286.
- Scraper tube 278 and scraper 288 are still in the extended position, as seen in Figure 7E . If seal pad 280 is engaged with the borehole wall, snorkel extension 266, screen inlet end 294 and the top of scraper 288 pierce the mudcake that has been sealed off, and preferably go through the entire mudcake layer and into formation 9.
- Floating scraper 288 is used to clear the debris in a similar fashion to that described with respect to formation probe assembly 50.
- a downward force is applied to scraper tube 278, preferably by applying a hydraulic fluid force downward on flange 372 of scraper tube 278.
- the cavity formed by scraper tube 278 and inner snorkel surface 269 fills with hydraulic fluid as scraper tube 278 moves downward, until tube flange 372 seats on scraper tube keeper 270.
- scraper 288 As scraper 288 is drawn within snorkel extension 266 during this process, scraper 288 passes through screen 290, agitating and removing debris that has gathered on screen 290 through frictional engagement between scraper 288 and screen 290, as previously described. Also previously described was an alternative embodiment including a rotating screen 290, equally applicable here.
- apertures 289 radially align with screen outlet end 296 such that fluid communication is possible between screen bore 292 and passageway 279 of scraper tube 278. This scraper 288 action that removes debris is preferably performed as part of the formation probe assembly 200 retract sequence, as described below.
- forces may be applied to probe assembly 200 in opposite directions relative to the extending forces. Simultaneously, the extending forces may be reduced or ceased to aid in probe retraction.
- a pressure differential is applied across flange 372 of scraper tube 278 by increasing the hydraulic fluid pressure on the bottom of flange 372. This extends scraper tube 278 until scraper 288 is fully extended once again, wiping screen 290 clean as scraper 288 passes through it.
- a hydraulic force is applied to snorkel base portion 262 at shoulder 352 to push snorkel assembly 260 down until retaining edge 273 of scraper tube keeper 270 sits on retainer ring 277, thereby fully retracting snorkel assembly 260.
- a hydraulic force is applied downward on piston base portion 244 at shoulder 342 until base portion 244 seats on capture sleeve 254 and retainer ring 256 adjacent outer piston base portion 234.
- a hydraulic fluid is inserted at adapter sleeve shoulder 332 onto outer piston base portion 234 to force outer piston 230 downward.
- Outer piston 230 then seats on bottom 207 of aperture 204, and the piston 240/snorkel 260 assembly seats on stem plate 210, thereby fully retracting probe assembly 200.
- probe retract switch 276 is triggered as described above, signaling a successful retraction of assembly 200.
- formation probe assembly 50 may only extend the outer end of piston extending portion 119 past the outer end of sleeve 94 a distance that is less than the length of piston 96.
- the length of piston 96 is defined as the distance between the uppermost end of extending portion 119 and the lowermost end of base portion 118.
- probe assembly 200 may extend the outer end of piston upper portion 250 past the outer end of sleeve 220 a distance that exceeds the length of piston 240. Therefore, the telescoping feature of probe assembly 200, i.e., the concentric pistons 230, 240, allows seal pad 280 to engage a borehole wall that is significantly further from collar 202 than the length of piston 240.
- the test sequence 700 may begin (box 702) upon a command to the tool 10 from the surface of the borehole, for example, or from embedded tool software.
- piston 96 and seal pad 180 may be extended (box 704).
- piston 230 may be extended (box 703) to provide the telescopic effect previously described.
- the borehole wall is contacted by seal pad 180 (box 706).
- a volume surrounding snorkel 98 is sealed (box 708).
- seal pad 180 may be filled with a fluid (box 707), as previously described.
- snorkel 98 may be extended (box 710), and the borehole wall contacted by snorkel 98 (box 712).
- Scraper 160 may now be retracted (box 714), causing agitation and removal of contaminants from snorkel 98.
- a formation property may then be measured (box 716).
- contaminants may be filtered (box 715), such as by a screen 100.
- snorkel 98 is retracted (box 718), piston 96 and seal pad 180 are retracted (box 720), and scraper 160 is extended (box 722).
- the extension of scraper 160 may also serve to remove contaminants from snorkel 98.
- Sequence 700 ends (box 724) with a formation property having been measured for uses further described herein.
- formation probe assemblies 50, 200 may be located elsewhere in the tool.
- formation probe assembly 50 may instead be disposed in blade 37 of stabilizer 36.
- Equalizer valve 60, shutoff valve 74 and draw down pistons 70, 72 may remain in the same position as shown in Figure 3B , although it is preferred that they be in closer proximity to formation probe assembly 50, and therefore may be moved closer to stabilizer 36.
- Locating formation probe assemblies 50, 200 in stabilizer blade 37 allows the assemblies to be placed closer to the borehole wall while still mounted in a robust portion of the tool.
- the other blades of stabilizer 36 may be used to back up formation probe assemblies 50, 200 as they extend out and pressure up against the borehole wall.
- the blades of stabilizer 36 are preferably used to back up the extending formation probe assemblies 50, 200.
- a reactive force must be applied to the tool to counter the force of the extending probe.
- centralizing pistons such as those illustrated and described in U.S. Patent Application Serial No. 10/440,593, filed May 19, 2003 and entitled "Method and Apparatus for MWD Formation Testing," hereby incorporated by reference for all purposes, may be used.
- a probe assembly position indicator may be included in the probe assembly to measure the distance that the probe assembly has extended from its fully retracted position. Numerous sensors may be used to detect the position of the probe assembly as it extends.
- the probe assembly position indicator may be a measure of the volume of hydraulic fluid used to extend the probe assembly. If the probe assembly is configured to use hydraulic fluid and pressure differentials to extend, as is described in the embodiments above, the volume of fluid pumped into the probe assembly may be measured. With known diameters for the adapter sleeves and pistons, the distance that the pistons have extended may be calculated using the volume of fluid that has been pumped into the probe assembly. To make this measurement more accurate, certain characteristics of the probe assembly may be accounted for, such as seal pad compression as it compresses against the borehole wall.
- an optical or acoustic sensor may be disposed in the probe assembly, such as in an aperture formed in the piston surface 141 of formation probe assembly 50, or piston surface 242 of probe assembly 200.
- the optical or acoustic sensor may measure the distance the piston moves from a known reference point, such as the piston position when the probe assembly is fully retracted.
- a known reference point such as the piston position when the probe assembly is fully retracted.
- a potentiometer, resistance-measuring device or other such device well known to one skilled in the art may be used to detect movement of the reciprocating portions of the probe assemblies through electrical means.
- the potentiometer or resistance-measuring device may measure voltage or resistance, and such information can be used to calculate distance.
- the distance measurement gathered from the probe position indicator may be used for numerous purposes.
- the borehole caliper may be calculated using this measurement, thereby obtaining an accurate measurement of the borehole diameter.
- multiple probes may be spaced radially around the drill string or wireline instrument, and measurements may be taken with the multiple probes to obtain borehole diameter and shape. Having an accurate borehole caliper measurement allows the driller to know where borehole breakout or collapse may be occurring.
- the caliper measurement may also be used to help correct formation evaluation sensors. For example, resistivity measurements are affected by borehole size. Neutron corrections applied to a neutron tool are also affected, as well as density corrections applied to a density tool. Other sensor tools may also be affected. An accurate borehole caliper measurement assists in correcting these tools, as well as any other drilling, production and completion process that requires borehole size characteristics, such as cementing.
- the probe position indicator may be used to correct for probe flow line volume changes.
- Flow lines such as flow lines 91, 93 in Figures 6A , 6B and 9 , are susceptible to volume changes as the probe seal pad compresses and decompresses. Particularly, when the seal pad is engaged with the borehole wall and a formation test is in progress, the pressure from drawing down the formation fluids causes the seal pad to compress and the flow line volume to increase.
- the flow line volume is used in several formation calculations, such as mobility; permeability may then be calculated using formation fluid viscosity and density. To correct for this volume change and obtain an accurate flow line volume measurement, probe positioning may be used.
- the probe position may be used to correct for the portion of the flow line volume that is not being used.
- the embodiments of the position indicator described above may also be applied to the draw down piston assemblies, described in more detail below, for knowing where in the cylinder the draw down piston is located, and how the piston is moving. Volume and diameter calculations may be used to obtain distance moved, or sensors may be used as described above. Thus, the exact distance the piston has moved may be obtained, rather than relying on the volume of fluid used to actuate the piston as an indication of distance moved. Further, the steadiness of the draw down may be obtained from the position indicator. The rate may be calculated from the distance measured, and the steadiness of the rate may be used to correct other measurements.
- a reference pressure may be chosen to draw down to, and then the distance the draw down piston moved before that reference pressure was reached may be measured by the draw down piston position indicator. If the bubble point is reached, the distance the piston moved may be recorded and sent to the surface, or to the software in the tool, so that the piston may be commanded to move less and thereby avoid the bubble point.
- Sensors intended for other purposes may also be disposed in the probe assemblies.
- a temperature sensor known to one skilled in the art, may be disposed on the probe assembly for taking annulus or formation temperature.
- the temperature sensor may be placed in the snorkel extensions 126, 266. In the probe assembly retracted position, the sensor would be adjacent the annulus environment, and the annulus temperature could be taken. In the probe assembly extended position, the sensor would be adjacent the formation, allowing for a formation temperature measurement.
- Such temperature measurements could be used for a variety of reasons, such as production or completion computations, or evaluation calculations such as permeability and resistivity.
- These sensors may also be placed adjacent the probe assemblies, such as in the stabilizer blades or centralizing pistons.
- draw down piston assembly 70 generally includes annular seal 502, piston 506, plunger 510 and endcap 508. Piston 506 is slidingly received in cylinder 504 and plunger 510, which is integral with and extends from piston 506, is slidingly received in cylinder 514. In Figure 11 , piston 506 is in its drawn down position, but is typically biased to its uppermost or shouldered position at shoulder 516. A bias spring (not shown) biases piston 506 to the shouldered position, and is disposed in lower cylinder portion 504b between piston 506 and endcap 508.
- Cylinder 512 is the upper portion of cylinder 514 that is in fluid communication with the longitudinal passageway 93 (seen schematically in Figure 9 ) that interconnects with draw down shutoff valve assembly 74, draw down piston 72, formation probe assembly 50, 200 and equalizer valve 60. Cylinder 512 is flooded with drilling fluid via its interconnection with passageway 93. Cylinder 514 is filled with hydraulic fluid beneath seal 513 via its interconnection with hydraulic circuit 400.
- Endcap 508 houses a contact switch (not shown) having a contact that faces toward piston 506.
- a wire 515 is coupled to the contact switch.
- a plunger 511 is disposed in piston 506.
- Draw down piston 72 is similar to piston 70, with the most notable difference being that the draw down volume is greater and the assembly does not include a bias spring.
- Draw down piston assembly 72 generally includes annular seal 532, piston 536, plunger 540 and endcap 538. Piston 536 is slidingly received in cylinder 534 and plunger 540, which is integral with and extends from piston 536, is slidingly received in cylinder 544. Plunger 540 and cylinder 544 have greater diameters than the corresponding portions of piston 70.
- piston 536 is in its drawn down position, but is typically maintained at its uppermost or shouldered position at shoulder 546 by hydraulic force.
- Cylinder 542 is the upper portion of cylinder 544 that is in fluid communcation with the longitudinal passageway 93 (seen schematically in Figure 9 ) that interconnects with draw down shutoff valve assembly 74, draw down piston 70, formation probe assembly 50, 200 and equalizer valve 60. Cylinder 542 is flooded with drilling fluid via its interconnection with passageway 93. Cylinder 544 is filled with hydraulic fluid beneath seal 543 via its interconnection with hydraulic circuit 400.
- Endcap 538 houses a contact switch 548 having a contact 550 that faces toward piston 536.
- a wire 545 is coupled to contact switch 548.
- a plunger 541 is disposed in piston 536.
- draw down pistons may vary in size such that their volumes vary.
- the pistons may also be configured to draw down at varying pressures.
- the embodiment just described includes two draw down piston assemblies, but the formation tester tool may include more or less than two.
- the hydraulic circuit 400 used to operate formation probe assemblies 50, 200. equalizer valve 60 and draw down pistons 70, 72 is shown in Figure 9 .
- a microprocessor-based controller 402 is electrically coupled to all of the controlled elements in the hydraulic circuit 400 illustrated in Figure 9 , although the electrical connections to such elements are conventional and are not illustrated other than schematically.
- Controller 402 is located in electronics module 20, shown in Figure 2A , although it could be housed elsewhere in tool 10 or bottom hole assembly 6. Controller 402 detects the control signals transmitted from a master controller 401 housed in the MWD sub 13 of the bottom hole assembly 6 which, in turn, receives instructions transmitted from the surface via mud pulse telemetry, or any of various other conventional means for transmitting signals to downhole tools.
- controller 402 When controller 402 receives a command to initiate formation testing, the drill string has stopped rotating if tool 10 is disposed on a drill sting.
- motor 404 is coupled to pump 406 which draws hydraulic fluid out of hydraulic reservoir 408 through a serviceable filter 410.
- the pump 406 directs hydraulic fluid into hydraulic circuit 400 that includes formation probe assembly 50, 200 (either can be used interchangeably), equalizer valve 60, draw down pistons 70, 72 and solenoid valves 412, 414, 416, 418, 420, 422. It will be understood that although the description below will reference only formation probe assembly 50, the hydraulic circuit described may be used to operate formation probe assembly 50 or probe assembly 200.
- controller 402 In response to an electrical control signal, controller 402 energizes retract solenoid valve 412 and valve 414, and starts motor 404. Pump 406 then begins to pressurize hydraulic circuit 400 and, more particularly, charges probe retract accumulator 424. The act of charging accumulator 424 also ensures that the formation probe assembly 50 is retracted, the equalizer valve 60 is open and that draw down pistons 70, 72 are in their initial shouldered position as described with reference to Figures 11 and 12 . When the pressure in system 400 reaches a predetermined value, such as 1800 p.s.i.
- controller 402 (which continuously monitors pressure in the system) energizes extend solenoid valve 416 which causes formation probe assembly 50 to begin to extend toward the borehole wall 16. Concurrently, check valve 428 and relief valve 429 seal the probe retract accumulator 424 at a pressure charge of between approximately 500 to 1250 p.s.i. Solenoid valve 412 is still energized.
- Formation probe assembly 50 extends, as previously described, from the position shown in Figure 6A to a position before full extension as shown in Figure 6B (except with snorkel still retracted), where seal pad 180 engages the mud cake 49 on borehole wall 16.
- retract solenoid valve 412 is de-energized, thereby allowing snorkel 98 to be extended and scraper 160 to be retracted.
- the snorkel With hydraulic pressure continuing to be supplied to the extend side of piston 96 and snorkel 98 for formation probe assembly 50, the snorkel may then penetrate the mud cake and the scraper retracted, as shown in Figure 6B (and Figures 7E-7F for assembly 200).
- the outward extensions of pistons 96 and snorkel 98 continue until seal pad 180 engages the borehole wall 16, as previously described with regard to formation probe assembly 50.
- De-energizing solenoid valve 412 also closes equalizer valve 60, thereby isolating fluid passageway 93 from the annulus. In this manner, valve 412 ensures that valve 60 closes only after the seal pad 140 has entered contact with mud cake 49 which lines borehole wall 16. Passageway 93, now closed to the annulus 15, is in fluid communication with cylinders 512, 542 at the upper ends of cylinders 514, 544 in draw down piston assemblies 70, 72, best shown in Figures 11 and 12 .
- extend solenoid valve 416 With extend solenoid valve 416 still energized, and the hydraulic circuit 400 at approximately 1,200 p.s.i., probe extend accumulator 430 has been charged and controller 402 energizes solenoid valve 414. Energizing valve 414 closes off the extend section of the hydraulic circuit, thereby maintaining the extend section at approximately 1,200 p.s.i. and allowing drawdown to begin. With valve 414 energized, pressure can be added to the draw down circuit, which generally includes draw down accumulator 432, solenoid valves 418, 420, 422 and draw down piston assemblies 70, 72.
- Controller 402 now energizes solenoid valve 420 which permits pressurized fluid to enter portion 504a of cylinder 504 causing draw down piston 70 to retract.
- plunger 510 moves within cylinder 514 such that the volume of fluid passageway 93 increases by the volume of the area of the plunger 510 times the length of its stroke along cylinder 514.
- the volume of cylinder 512 is increased by this movement, thereby increasing the volume of fluid in passageway 93.
- these elements are sized such that the volume of fluid passageway 93 is increased by preferably 30 cc maximum as a result of piston 70 being retracted.
- controller 402 may energize solenoid valve 418 to pressurize the draw down shutoff valve assembly 74. Pressurizing valve assembly 74 causes draw down piston 70 to cease drawing down formation fluids. Now, valve assembly 74 and draw down piston 70 have been pressured up to approximately 1,800 p.s.i. This ensures that shutoff valve assembly 74 holds draw down piston 70 in its drawn down, or partially drawn down, position such that the drawn formation fluids are retained and not inadvertently expelled.
- solenoid valve 418 can be de-energized, thereby turning shutoff valve 74 off.
- Draw down with draw down piston 70 then commences until the volume of cylinder 514 filled.
- the draw down of draw down piston 70 may continue to be interrupted using valves 418 and 74. Such interruptions may be necessary to change draw down parameters, such as draw down rate and volume.
- Controller 402 may be used to command draw down piston 70 to draw down fluids at differing rates and volumes. For example, draw down piston 70 may be commanded to draw down fluids at 1cc per second for 10 cc and then wait 5 minutes. If the results of this test are unsatisfactory, a downlink signal may be sent using mud pulse telemetry, or another form of downhole communication, programming controller 402 to command piston 70 to now draw down fluids at 2cc per second for 20 cc and then wait 10 minutes, for example.
- the first test may be interrupted, parameters changed and the test may be restarted with the new parameters that have been sent from the surface to the tool. These parameter changes may be made while formation probe assembly 50 is extended.
- controller 402 may energize solenoid valve 422 which permits pressurized fluid to enter portion 534a of cylinder 534 causing draw down piston 72 to retract.
- plunger 540 moves within cylinder 534 such that the volume of fluid passageway 93 increases by the volume of the area of the plunger 540 times the length of its stroke along cylinder 544.
- the volume of cylinder 542 is increased by this movement, thereby increasing the volume of fluid in passageway 93.
- these elements are sized such that the volume of fluid passageway 93 is increased by 50 cc as a result of piston 72 being retracted.
- draw down piston 72 does not have the stop and start feature of piston 70, and is able to draw down more fluids at a faster rate.
- draw down piston 72 may be configured to draw down fluids at rates of 3.8 or 7.7 cc per second, for example.
- piston 70, 72 may be different sizes, and piston 72 may also be configured to have the stop and start feature via the shutoff valve assembly.
- hydraulic circuit 400 may be configured to operate multiple pistons 70 and/or multiple pistons 72.
- pistons 70, 72 may be operated in any order.
- draw down pistons 70, 72 as described above also allows the operator to purge fluids in the draw down piston assemblies and probe flow lines. For example, if a pre-test volume of fluid has been drawn into the probe, it may be purged by actuating the draw down pistons in the opposite directions. This may be useful for cleaning out any accumulated debris in the flow lines and probe assembly.
- a mechanical filter may be placed in the flow lines, such as anywhere along flow lines 91, 93 in Figures 6A , 6B and 9 .
- the flow lines may be purged by opening equalizer valve 60, pumping out fluids present in the flow lines, then closing equalizer valve 60 in preparation of another draw down sequence.
- draw down piston 70 As draw down piston 70 is actuated, 30 cc of formation fluid will thus be drawn through central passageway 127 of snorkel 98 and through screen 100.
- the movement of draw down piston 70 within its cylinder 504 lowers the pressure in closed passageway 93 to a pressure below the formation pressure, such that formation fluid is drawn through screen 100 and into apertures 166, through snorkel 98, then through stem passageway 108 to passageway 91 that is in fluid communication with passageway 93 and part of the same closed fluid system.
- fluid chambers 93 (which include the volume of various interconnected fluid passageways, including passageways in formation probe assembly 50, passageways 91, 93, the passageways interconnecting 93 with draw down pistons 70, 72 and draw down shutoff valve 74) preferably has a volume of approximately 63 cc. If draw down piston 72 is also activated, this volume should increase approximately 30 cc, up to approximately 90 cc total.
- Drilling mud in annulus 15 is not drawn into snorkel 98 because seal pad 180 seals against the mud cake.
- Snorkel 98 serves as a conduit through which the formation fluid may pass and the pressure of the formation fluid may be measured in passageway 93 while seal pad 180 serves as a seal to prevent annular fluids from entering the snorkel 98 and invalidating the formation pressure measurement.
- formation fluid is drawn first into the central bore 132 of screen 100. It then passes through slots 134 in screen slotted segment 133 such that particles in the fluid are filtered from the flow and are not drawn into passageway 93.
- the formation fluid then passes between the outer surface of screen 100 and the inner surface of snorkel extension 126 where it next passes through outlet end 135, apertures 166 in scraper 160, scraper tube 150 and into the central passageway 108 of stem 92.
- Screen 100 (and screen 290 of assembly 200) may be optimized for particular applications. For example, if prior knowledge of the formation is obtained, then the screen can be tailored to the type of rock or sediment that is present in the formation.
- One type of adjustable screen is a gravel-packed screen, which may be used instead of or in conjunction with the slotted screen 100.
- a gravel-packed screen is two longitudinal, cylindrical screens of different diameters. The screens are disposed concentrically and the annulus is filled with gravel pack sieve, or a known sand size.
- the gravel pack may be tailored to have a 10-to-1 ratio of formation sand size to gravel pack size, which is the preferable formation particle size to gravel particle size ratio. With this ratio, it is expected that the gravel pack screen will have the ability to screen formation particles up to 1/10 th the size of the nominal formation particle diameter size encountered. With this embodiment, the gravel pack sand size can be tailored to the specific intended application.
- the screens 100, 290 as they are illustrated in Figures 6B , 7F may be optimized by adjusting the size and number of slits required for a particular application.
- the slits, or slots are illustrated schematically as internally slotted segment 133 having slots 134 in Figure 6B , and internally slotted segment 293 having slots 295.
- the size and number of slits can be tailored to the particular formation expected to be intersected, and the nominal sand particle size of the produced sand. For example, more slits with smaller openings may be used for smaller nominal formation particle size.
- the above mentioned adjustment of slot size may be accomplished real-time.
- the slot size is set upon deployment of tool 10 into the borehole. The slot size remains unchanged while tool 10 is deployed.
- the slot size may be adjusted at the surface of the borehole by replacing screens 100, 290, or by manually adjusting the slot sizes, but may not be adjusted real-time, or while tool 10 is deployed downhole.
- detection of the type of formation actually intersected may be achieved via the various apparatus and methods disclosed herein. If the detected formation value, such as particle size, differs from a predetermined value, the slot size may be adjusted without tripping tool 10 out of the borehole.
- a command may be given from the surface of the borehole, or from tool 10, and slot size may be adjusted by moving two concentrically disposed slotted cylindrical members relative to each other, for example, or by adjusting shutter mechanisms adj acent the slots.
- check valve 434 maintains the desired pressure acting against piston 96 and snorkel 98 to maintain the proper seal of seal pad 180. Additionally, because probe seal accumulator 430 is fully charged, should tool 10 move during drawdown, additional hydraulic fluid volume may be supplied to piston 96 and snorkel 98 to ensure that seal pad 180 remains tightly sealed against the borehole wall. In addition, should the borehole wall 16 move in the vicinity of seal pad 180, the probe seal accumulator 430 will supply additional hydraulic fluid volume to piston 96 and snorkel 98 to ensure that seal pad 180 remains tightly sealed against the borehole wall 16. Without accumulator 430 in circuit 400, movement of the tool 10 or borehole wall 16, and thus of formation probe assembly 50, could result in a loss of seal at seal pad 180 and a failure of the formation test.
- the pressure will stabilize enabling pressure transducers 426b,c to sense and measure formation fluid pressure.
- the measured pressure is transmitted to the controller 402 in the electronic section where the information is stored in memory and, alternatively or additionally, is communicated to the master controller 401 in the MWD tool 13 below formation tester 10 where it can be transmitted to the surface via mud pulse telemetry or by any other conventional telemetry means.
- pistons 70, 72 When drawdown is completed, pistons 70, 72 actuate their contact switches previously described.
- controller 402 When the contact switch 550, for example, is actuated controller 402 responds by shutting down motor 404 and pump 406 for energy conservation.
- Check valve 436 traps the hydraulic pressure and maintains pistons 70, 72 in their retracted positions. In the event of any leakage of hydraulic fluid that might allow pistons 70, 72 to begin to move toward their original shouldered positions, drawdown accumulator 432 will provide the necessary fluid volume to compensate for any such leakage and thereby maintain sufficient force to retain pistons 70, 72 in their retracted positions.
- controller 402 continuously monitors the pressure in fluid passageway 93 via pressure transducers 426 b, c. When the measured pressure stabilizes, or after a predetermined time interval, controller 402 de-energizes extend solenoid valve 416. When this occurs, pressure is removed from the close side of equalizer valve 60 and from the extend side of probe piston 96. Equalizer valve 60 will return to its normally open state and probe retract accumulator 424 will cause piston 96 and snorkel 98 to retract, such that seal pad 180 becomes disengaged with the borehole wall. Thereafter, controller 402 again powers motor 404 to drive pump 406 and again energizes solenoid valve 412. This step ensures that piston 96 and snorkel 98 have fully retracted and that the equalizer valve 60 is opened.
- the formation tool has a redundant probe retract mechanism. Active retract force is provided by the pump 406. A passive retract force is supplied by probe retract accumulator 424 that is capable of retracting the probe even in the event that power is lost. It is preferred that accumulator 424 be charged at the surface before being employed downhole to provide pressure to retain the piston and snorkel in housing 12.
- equalizer valve 60 may be opened in a similar manner at other times during probe engagement with the borehole wall. If the probe seal pad is in danger of becoming stuck on the borehole wall, the suction may be broken by opening equalizer valve 60 as described above.
- controller 402 After a predetermined pressure, for example 1800 p.s.i., is sensed by pressure transducer 426a and communicated to controller 402 (indicating that the equalizer valve is open and that the piston and snorkel are fully retracted), controller 402 de-energizes solenoid valves 418, 420, 422 to remove pressure from sides 504a, 534a of drawdown pistons 70, 72, respectively. With solenoid valve 412 remaining energized, positive pressure is applied to sides 504b, 534b of drawdown pistons 70, 72 to ensure that pistons 70, 72 are returned to their original positions.
- solenoid valve 412 With solenoid valve 412 remaining energized, positive pressure is applied to sides 504b, 534b of drawdown pistons 70, 72 to ensure that pistons 70, 72 are returned to their original positions.
- Controller 402 monitors the pressure via pressure transducer 426a and when a predetermined pressure is reached, controller 402 determines that pistons 70, 72 are fully returned and it shuts off motor 404 and pump 406 and de-energizes solenoid valve 412. With all solenoid valves returned to their original positions and with motor 404 off, tool 10 is back in its original condition.
- the hydraulic circuit 400 may also act as a regenerative circuit while extending the probe assembly.
- retract valve 412 and extend valve 416 energized or actuated, as described above, and the difference in areas between the smaller area on the retract side of the probe piston, such as piston 96 or piston 240, and the larger area on the extend side of the piston, there is a net effect of extending the probe assembly.
- retract valve 412 As the piston continues to extend with retract valve still open, there is a back flow of hydraulic fluid through retract valve 412 due to the lack of a check valve behind retract valve 412. This relatively unimpeded back flow path leads into the pressurized hydraulic fluid flowing into extend valve 416, adding to the pressure on the extend side of the circuit and increasing the rate at which the probe may extend.
- circuit 400 During extension of the probe assembly, using hydraulic circuit 400, it can be seen that the total volume of hydraulic fluid required to be displaced by pump 406, and hence the number of revolutions of motor 404, is reduced compared to a non-regenerative circuit.
- the regenerative nature of circuit 400 also allows the moveable wiper or scraper, such as scraper 160, to remain extended during extension of the probe assembly, especially as the snorkel assembly is penetrating the mudcake and formation and there is an extra force pushing back on the moveable scraper.
- the area of the extend side of the scraper assembly is greater than the area of the retract side, or the upper side of flange 372.
- the same hydraulic pressure acts on different areas, causing the wiper element to extend and the pressurized fluid to regenerate on the extend side of the scraper tube 278, as previously described.
- the regeneration of pressure in circuit 400 allows faster extension of the probe assembly.
- the regenerated pressure assists with control of equalizer valve actuation.
- a hydraulic reservoir accumulator assembly 600 is disposed in probe collar 12 as shown in Figure 10I .
- Reservoir accumulator assembly 600 maintains a pressure above the annulus or surrounding environment pressure in the complete tool 10 hydraulic system. This condition in the hydraulic system compensates for pressure and temperature changes in the tool. Also, the pressure provided from assembly 600 causes pump 406 ( Figure 9 ) to begin operating from the annulus pressure, thereby reducing the work load that would be required from starting pump 406 at atmospheric pressure.
- accumulator assembly 600 may be used to communicate annulus pressure into the tool's hydraulic system. As will be seen below, assembly 600 is self contained and easily field replaceable.
- Assembly 600 generally includes a body 602 having a top surface 632, bottom surface 634 ( Figure 10C ) and endcap 604 at end 606, several locking wings 608 and drilling fluid apertures 618, 620 at end 622.
- Top surface 632 includes additional fluid apertures 628, 630 covered by a screen 639 as illustrated in Figure 10F . Screen 639 is held in place by retaining ring 637, and prevents large particles in the drilling fluid from entering the cylinders and interfering with the reciprocation of the pistons.
- Endcap 604 includes a pressure plug 638 for connecting assembly 600 to probe collar 12, which helps to lock assembly 600 into place as illustrated in Figure 10H .
- Endcap 604 also includes hydraulic fluid check valves 640, 642 for fluid communication with the tool hydraulic circuit, and for checking fluid into assembly 600 and the tool hydraulic system when assembly 600 is removed from collar 12.
- Figure 10F it can be seen that the inside of assembly 600 is split into two cylinders 626, 646.
- Figure 10C illustrates cylinder 626 retaining a piston 636 which separates cylinder 626 into hydraulic fluid portion 626a and drilling fluid portion 626b.
- Piston 636 is reciprocal between the position shown in Figure 10C and the position of piston 656 shown in Figure 10D .
- Spring 624 is retained in cylinder portion 626b between piston 636 and end 622. Spring 624 extends past piston end 636b around piston 636 and seats on increased piston diameter portion 633.
- Increased diameter portion 633 is similar to increased diameter portion 653 of piston 656, illustrated in Figure 10G .
- aperture 620 allows drilling fluids to enter cylinder portion 626b and exert the surrounding annulus pressure on side 636b of piston 636. Because spring 624 also exerts a force on side 636b, the pressure of hydraulic fluid in cylinder portion 626a is greater than the annulus pressure. The pressure of the hydraulic fluid in cylinder portion 626a is the annulus pressure plus the pressure added by spring 624. Spring 624 may exert, for example, a pressure of approximately 60-80 p.s.i.
- Cylinder 646 of Figure 10D operates in a similar fashion to cylinder 626. Drilling fluid enters cylinder portion 646b through aperture 622, thereby exerting the annulus pressure on side 656b of piston 656. Spring 644 then increases the pressure on piston 656, causing the hydraulic fluid in cylinder 646a, and therefore the hydraulic fluid in the tool hydraulic system, to be greater than the annulus pressure. Spring 644 is shown in the fully compressed position in Figure 10D .
- enlarged piston end 656a includes seal 659 for sealing the drilling mud from the system hydraulic fluid, and scraper 661 for cleaning the cylinder bore 646 as piston 656 reciprocates.
- Spring 644 seats on increased diameter portion 653.
- Piston end 636a is similar to piston end 656a illustrated in Figure 10G .
- pistons 636, 656 reciprocate independently of each other while maintaining the pressure in the hydraulic system of the tool. Also, both pistons communicate with the entire tool hydraulic system.
- accumulator assembly 600 is illustrated placed into position in collar 12, but not locked down.
- assembly 600 is disposed above cavity 601 and locking wings 608 ( Figure 10A ) are aligned with recesses 664.
- Recesses 664 are L-shaped (not shown) with the bottom portions of the L extending toward endcap 604 and end 603 of cavity 601. Assembly 600 is lowered into cavity 601 with locking wings 608 sliding down through recesses 664 until assembly 600 seats at the bottom of cavity 601 and top surface 632 is substantially flush with the surface of collar 12.
- Assembly 600 is then moved toward cavity end 603 such that locking wings 608 move into the extending bottom portions of recesses 664 and pressure plug 638 ( Figure 10A ) pressure fits into an aperture (not shown) disposed at end 603 of cavity 601. This forward movement also causes a gap 678 to be formed between cavity end 605 and assembly end 622.
- a wedge 670 is placed into gap 678.
- the angled end 622 (illustrated in Figure 10C ) matingly receives the angled side 676 of wedge 670. The wedging action of these mating surfaces ensures that assembly 600 is moved fully forward in cavity 601. Bolts 674 and nuts 672 lock down wedge 670. Further, L-shaped locking pieces 668 are placed into recesses 664 and bolts 666 are used to lock down wings 608.
- the final locked position of assembly 600 is illustrated in Figure 10I .
- Fluid ports 628, 630 communicate with drilling fluid in annulus 15. Fluid entering cylinder portions 626b and 646b through apertures 618, 620 is screened by slots in wedge 670 (slots not shown).
- Removing accumulator assembly 600 requires a process done in reverse of the process just described. While removing assembly 600, check valves 640, 642 close and maintain oil in the tool hydraulic system. Assembly 600 may then be cleaned and/or replaced. Check valves 640, 642 open again once assembly 600 is locked into position. Hydraulic fluid may then be added to make up for any fluid loss, and preferable fluid is added to the extent that pistons 636, 656 are pushed back to the position illustrated in Figure 10D .
- the uplink and downlink commands used by tool 10 are not limited to mud pulse telemetry.
- other telemetry systems may include manual methods, including pump cycles, flow/pressure bands, pipe rotation, or combinations thereof.
- Other possibilities include electromagnetic (EM), acoustic, and wireline telemetry methods.
- EM electromagnetic
- An advantage to using alternative telemetry methods lies in the fact that mud pulse telemetry (both uplink and downlink) requires pump-on operation but other telemetry systems do not.
- the down hole receiver for downlink commands or data from the surface may reside within the formation test tool or within an MWD tool 13 with which it communicates.
- the down hole transmitter for uplink commands or data from down hole may reside within the formation test tool 10 or within an MWD tool 13 with which it communicates.
- the receivers and transmitters are each positioned in MWD tool 13 and the receiver signals are processed, analyzed and sent to a master controller 401 in the MWD tool 13 before being relayed to local controller 402 in formation testing tool 10.
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Abstract
Description
- Not applicable.
- During the drilling and completion of oil and gas wells, it may be necessary to engage in ancillary operations, such as monitoring the operability of equipment used during the drilling process or evaluating the production capabilities of formations intersected by the wellbore. For example, after a well or well interval has been drilled, zones of interest are often tested to determine various formation properties such as permeability, fluid type, fluid quality, formation temperature, formation pressure, bubblepoint and formation pressure gradient. These tests are performed in order to determine whether commercial exploitation of the intersected formations is viable and how to optimize production.
- Wireline formation testers (WFT) and drill stem testing (DST) have been commonly used to perform these tests. The basic DST test tool consists of a packer or packers, valves or ports that may be opened and closed from the surface, and two or more pressure-recording devices. The tool is lowered on a work string to the zone to be tested. The packer or packers are set, and drilling fluid is evacuated to isolate the zone from the drilling fluid column. The valves or ports are then opened to allow flow from the formation to the tool for testing while the recorders chart static pressures. A sampling chamber traps clean formation fluids at the end of the test. WFTs generally employ the same testing techniques but use a wireline to lower the test tool into the well bore after the drill string has been retrieved from the well bore, although WFT technology is sometimes deployed on a pipe string. The wireline tool typically uses packers also, although the packers are placed closer together, compared to drill pipe conveyed testers, for more efficient formation testing. In some cases, packers are not used. In those instances, the testing tool is brought into contact with the intersected formation and testing is done without zonal isolation across the axial span of the circumference of the borehole wall.
- WFTs may also include a probe assembly for engaging the borehole wall and acquiring formation fluid samples. The probe assembly may include an isolation pad to engage the borehole wall. The isolation pad seals against the formation and around a hollow probe, which places an internal cavity in fluid communication with the formation. This creates a fluid pathway that allows formation fluid to flow between the formation and the formation tester while isolated from the borehole fluid.
- In order to acquire a useful sample, the probe must stay isolated from the relative high pressure of the borehole fluid. Therefore, the integrity of the seal that is formed by the isolation pad is critical to the performance of the tool. If the borehole fluid is allowed to leak into the collected formation fluids, a non-representative sample will be obtained and the test will have to be repeated.
- With the use of WFTs and DSTs, the drill string with the drill bit must be retracted from the borehole. Then, a separate work string containing the testing equipment, or, with WFTs, the wireline tool string, must be lowered into the well to conduct secondary operations. Interrupting the drilling process to perform formation testing can add significant amounts of time to a drilling program.
- DSTs and WFTs may also cause tool sticking or formation damage. There may also be difficulties of running WFTs in highly deviated and extended reach wells. WFTs also do not have flowbores for the flow of drilling mud, nor are they designed to withstand drilling loads such as torque and weight on bit.
- Further, the formation pressure measurement accuracy of drill stem tests and, especially, of wireline formation tests may be affected by filtrate invasion and mudcake buildup because significant amounts of time may have passed before a DST or WFT engages the formation. Mud filtrate invasion occurs when the drilling mud fluids displace formation fluids. Because the mud filtrate ingress into the formation begins at the borehole surface, it is most prevalent there and generally decreases further into the formation. When filtrate invasion occurs, it may become impossible to obtain a representative sample of formation fluids or, at a minimum, the duration of the sampling period must be increased to first remove the drilling fluid and then obtain a representative sample of formation fluids. The mudcake is made up of the solid particles that are deposited on the side of the well as the filtrate invades the near well bore during drilling. The prevalence of the mudcake at the borehole surface creates a "skin." Thus there may be a "skin effect" because formation testers can only withdraw fluids from relatively short distances into the formation, thereby distorting the representative sample of formation fluids due to the filtrate. The mudcake also acts as a region of reduced permeability adjacent to the borehole. Thus, once the mudcake forms, the accuracy of reservoir pressure measurements decreases, affecting the calculations for permeability and producibility of the formation.
- Another testing apparatus is the measurement while drilling (MWD) or logging while drilling (LWD) tester. Typical LWD/MWD formation testing equipment is suitable for integration with a drill string during drilling operations. Various devices or systems are provided for isolating a formation from the remainder of the wellbore, drawing fluid from the formation, and measuring physical properties of the fluid and the formation. With LWD/MWD testers, the testing equipment is subject to harsh conditions in the wellbore during the drilling process that can damage and degrade the formation testing equipment before and during the testing process. These harsh conditions include vibration and torque from the drill bit, exposure to drilling mud, drilled cuttings, and formation fluids, hydraulic forces of the circulating drilling mud, and scraping of the formation testing equipment against the sides of the wellbore. Sensitive electronics and sensors must be robust enough to withstand the pressures and temperatures, and especially the extreme vibration and shock conditions of the drilling environment, yet maintain accuracy, repeatability, and reliability.
- For a more detailed description of preferred embodiments of the present invention, reference will now be made to the accompanying drawings, wherein:
-
Figure 1 is a schematic elevation view, partly in cross-section, of an embodiment of a formation tester apparatus disposed in a subterranean well; -
Figures 2A-2C are elevation views, in cross-section, of portions of the bottomhole assembly and formation tester assembly shown inFigure 1 ; -
Figures 3A-3B are enlarged elevation views, in cross-section, of the formation tester tool portion of the formation tester assembly shown inFigures 2B-2C ; -
Figure 4 is an elevation view of the formation probe assembly and equalizer valve collar shown inFigure 3B ; -
Figure 5 is an enlarged cross-section view along line 5-5 ofFigure 4 ; -
Figure 6A is an enlarged view, in cross-section, of the formation probe assembly in a retracted position and equalizer valve shown inFigure 5 ; -
Figure 6B is an enlarged view, in cross-section, of the formation probe assembly along line 6-6 ofFigure 4 , the probe assembly being in an extended position; -
Figures 7A-7F are cross-sectional views of another embodiment of the formation probe assembly taken along the same line as seen inFigure 6B , the probe assembly being shown in a different position in each ofFigures 7A-7F ; -
Figure 8A is a schematic elevation view, in cross-section, of the probe retract switch portion of the formation probe assembly; -
Figure 8B is an enlarged view of the contact portion of the retract switch shown inFigure 8A ; -
Figure 9 is a schematic view of a hydraulic circuit employed in actuating the formation tester apparatus; -
Figure 10A is a top elevation view of a hydraulic reservoir accumulator assembly employed in the formation tester assembly; -
Figure 10B is an end view of the reservoir accumulator assembly ofFigure 10A ; -
Figure 10C is a cross-section view taken along line C-C ofFigure 10B ; -
Figure 10D is a cross-section view taken along line D-D ofFigure 10B ; -
Figure 10E is a cross-section view taken along line E-E ofFigure 10D ; -
Figure 10F is a cross-section view taken along line F-F ofFigure 10C ; -
Figure 10G is an enlarged view of the detail ofFigure 10D ; -
Figures 10H-10I are perspective views of the reservoir accumulator assembly and probe collar; -
Figures 11-13 are elevation views, in cross-section, of the draw down piston and shutoff valve assemblies disposed in the probe collar of the formation tester assembly; and -
Figure 14 is a flow diagram of a formation test sequence. - Certain terms are used throughout the following description and claims to refer to particular system components. This document does not intend to distinguish between components that differ in name but not function.
- In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to...". Also, the terms "couple," "couples", and "coupled" used to describe any electrical connections are each intended to mean and refer to either an indirect or a direct electrical connection. Thus, for example, if a first device "couples" or is "coupled" to a second device, that interconnection may be through an electrical conductor directly interconnecting the two devices, or through an indirect electrical connection via other devices, conductors and connections. Further, reference to "up" or "down" are made for purposes of ease of description with "up" meaning towards the surface of the borehole and "down" meaning towards the bottom or distal end of the borehole. In addition, in the discussion and claims that follow, it may be sometimes stated that certain components or elements are in fluid communication. By this it is meant that the components are constructed and interrelated such that a fluid could be communicated between them, as via a passageway, tube, or conduit. Also, the designation "MWD" or "LWD" are used to mean all generic measurement while drilling or logging while drilling apparatus and systems.
- To understand the mechanics of formation testing, it is important to first understand how hydrocarbons are stored in subterranean formations. Hydrocarbons are not typically located in large underground pools, but are instead found within very small holes, or pore spaces, within certain types of rock. Therefore, it is critical to know certain properties of both the formation and the fluid contained therein. At various times during the following discussion, certain formation and formation fluid properties will be referred to in a general sense. Such formation properties include, but are not limited to: pressure, permeability, viscosity, mobility, spherical mobility, porosity, saturation, coupled compressibility porosity, skin damage, and anisotropy. Such formation fluid properties include, but are not limited to: viscosity, compressibility, flowline fluid compressibility, density, resistivity, composition and bubble point.
- Permeability is the ability of a rock formation to allow hydrocarbons to move between its pores, and consequently into a wellbore. Fluid viscosity is a measure of the ability of the hydrocarbons to flow, and the permeability divided by the viscosity is termed "mobility." Porosity is the ratio of void space to the bulk volume of rock formation containing that void space. Saturation is the fraction or percentage of the pore volume occupied by a specific fluid (e.g., oil, gas, water, etc.). Skin damage is an indication of how the mud filtrate or mud cake has changed the permeability near the wellbore. Anisotropy is the ratio of the vertical and horizontal permeabilities of the formation.
- Resistivity of a fluid is the property of the fluid which resists the flow of electrical current. Bubble point occurs when a fluid's pressure is brought down at such a rapid rate, and to a low enough pressure, that the fluid, or portions thereof, changes phase to a gas. The dissolved gases in the fluid are brought out of the fluid so gas is present in the fluid in an undissolved state. Typically, this kind of phase change in the formation hydrocarbons being tested and measured is undesirable, unless the bubblepoint test is being administered to determine what the bubblepoint pressure is.
- In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
- Referring to
Figure 1 , aformation tester tool 10 is shown as a part ofbottom hole assembly 6 which includes anMWD sub 13 and adrill bit 7 at its lower most end.Bottom hole assembly 6 is lowered from adrilling platform 2, such as a ship or other conventional platform, viadrill string 5.Drill string 5 is disposed throughriser 3 andwell head 4. Conventional drilling equipment (not shown) is supported withinderrick 1 and rotatesdrill string 5 anddrill bit 7, causingbit 7 to form aborehole 8 through theformation material 9. Theborehole 8 penetrates subterranean zones or reservoirs, such asreservoir 11, that are believed to contain hydrocarbons in a commercially viable quantity. It should be understood thatformation tester 10 may be employed in other bottom hole assemblies and with other drilling apparatus in land-based drilling, as well as offshore drilling as shown inFigure 1 . In all instances, in addition toformation tester 10, thebottom hole assembly 6 contains various conventional apparatus and systems, such as a down hole drill motor, rotary steerable tool, mud pulse telemetry system, measurement-while-drilling sensors and systems, and others well known in the art. - It should also be understood that, even though
formation tester 10 is shown as part ofdrill string 5, the embodiments of the invention described below may be conveyed downborehole 8 via wireline technology, as is partially described above, or via a rotary steerable drill string that is well known to one skilled in the art. Further context and examples for methods of use of the embodiments described herein may be obtained from U.S. Patent Application entitled "Methods for Using a Formation Tester," having U.S. Express Mail Label Number EV 303483362 US and Attorney Docket Number 1391-54101; and U.S. Patent Application entitled "Methods for Measuring a Formation Supercharge Pressure," havingU.S. Patent ; each hereby incorporated herein by reference for all purposes.Application Serial Number 11/069,649 - Referring now to
Figures 2A-C , portions of theformation tester tool 10 are shown.Figure 2A illustrates theelectronics module 20, which may include battery packs, various circuit boards, capacitors banks and other electrical components.Figure 2B showsfillport assembly 22 havingfillports tool 10. Belowfillport assembly 22 ishydraulic insert assembly 30. Belowassembly 30 is the hydraulicconnectors ring assembly 32, which acts as a hydraulic line manifold.Figure 2C illustrates the portion oftool 10 includingequalizer valve 60, formation probe assembly 50 (or probe assembly 200), draw downshutoff valve assembly 74, draw downpiston assemblies stabilizer 36. Also included ispressure instrument assembly 38, including the pressure transducers used byformation probe assemblies - Referring to
Figures 3A-B now, the enlarged portions oftool 10 shown inFigures 2B-C are shown.Hydraulic insert assembly 30, probe retractaccumulator 424,equalizer valve 60,formation probe assembly 50, draw downshutoff valve 74 and draw downpiston assemblies Equalizer valve 60 may be any of a variety of equalizer valves known to one skilled in the art. - Referring now to
Figure 4 ,formation probe assembly 50 is disposed withinprobe drill collar 12, and covered byprobe cover plate 51. Also disposed withinprobe collar 12 is anequalizer valve 60 having avalve cover plate 61. Adjacentformation probe assembly 50 andequalizer valve 60 is a flat 136 in thesurface 17 ofprobe collar 12.Probe drill collar 12 includes a draw downcover 76 for protecting other devices associated with theformation probe assembly 50 mounted in thecollar 12, such as draw down pistons (not shown). - As best shown in
Figure 5 , it can be seen howformation probe assembly 50 andequalizer valve 60 are positioned inprobe collar 12.Formation probe assembly 50 andequalizer valve 60 are mounted inprobe collar 12 just above theflowbore 14.Flowbore 14 may be deviated from the centerlongitudinal axis 12a ofprobe collar 12, or fromother portions flowbore 14, to accommodate at leastformation probe assembly 50. For example, inFigure 5 ,flowbore portion 14a is offset radially from thelongitudinal axis 12a, and also from theflowbore portion 14b viatransition flowbore portion 14c. Also shown are draw downpiston assemblies shutoff valve 74. - The details of a first embodiment of
formation probe assembly 50 are best shown inFigure 6A-6B . InFigure 6A ,formation probe assembly 50 is retained inprobe collar 12 by threaded engagement withcollar 12 and also bycover plate 51.Formation probe assembly 50 generally includesstem 92, a generally cylindrical threadedadapter sleeve 94,piston 96 adapted to reciprocate withinadapter sleeve 94, and asnorkel assembly 98 adapted for reciprocal movement withinpiston 96. Probecollar 12 includes anaperture 90 for receivingformation probe assembly 50.Cover plate 51 fits over the top offormation probe assembly 50 and retains and protectsformation probe assembly 50 when theformation probe assembly 50 is withinprobe collar 12.Formation probe assembly 50 may extend and retract throughaperture 52 incover plate 51. -
Stem 92 includes acircular base portion 105 with anouter flange 106 having stem holding screw 97 (shown inFigure 6B ) for retainingstem 92 inaperture 90. Extending frombase 105 is atubular extension 107 havingcentral passageway 108. The end ofextension 107 includes internal threads at 109.Central passageway 108 is in fluid connection with fluid passageway 91 (not shown, but seen schematically inFigure 9 ) that connects to fluid passageway 93 (not shown, but seen schematically inFigure 9 ) leading to other portions oftool 10, includingequalizer valve 60. -
Adapter sleeve 94 includesinner end 111 that engagesflange 106 ofstem 92.Adapter sleeve 94 is secured withinaperture 90 by threaded engagement withcollar 12 atsegment 110. Theouter end 112 ofadapter sleeve 94 may extend to be substantially flushed withrecess 55 formed incollar 12 for receivingcover plate 51.Outer end 112 also includesflange 158 for engagingrecess 162 ofcover plate 51.Adapter sleeve 94 includes cylindricalinner surface 113 having reduceddiameter portions seal 116 is disposed insurface 114. -
Piston 96 is slidingly retained withinadapter sleeve 94 and generally includes cylindricalouter surface 141 having an increaseddiameter base portion 118. Aseal 143 is disposed in increaseddiameter portion 118. Just belowbase portion 118,piston 96 may rest onflange 106 ofstem base portion 105 whileformation probe assembly 50 is in the fully retracted position as shown inFigure 6A .Piston 96 may also include cylindrical inner surface 145 having reduced diameter portion 147.Piston 96 may further includecentral bore 121 having abore surface 120 and extending through upper extendingportion 119. - Referring to
Figure 6B , at the top of extendingportion 119 ofpiston 96 is aseal pad 180.Seal pad 180 may be donut-shaped with a curvedouter sealing surface 183 andcentral aperture 186. However,seal pad 180 may include numerous other geometries as is known in the art, or, for example, as is seen inU.S. Patent Application No. 10/440,835 entitled "MWD Formation Tester."Base surface 185 ofseal pad 180 may be coupled to askirt 182.Seal pad 180 may be bonded toskirt 182, or otherwise coupled toskirt 182, such as bymolding seal pad 180 ontoskirt 182 such that the seal pad material fills grooves or holes inskirt 182, as can be seen inU.S. Patent Application No. 10/440,835 .Skirt 182 is detachably coupled to extendingportion 119 by way of threaded engagement withsurface 120 of central bore 121 (seeFigure 6A ), or other means of engagement, such as a pressure fit withcentral bore surface 120. Because the seal pad/skirt combination may be detachable from extendingportion 119, it is easily replaced in the field. Alternatively,seal pad 180 may be coupled directly to extendingportion 119 without using a skirt. -
Seal pad 180 is preferably made of an elastomeric material.Seal pad 180 seals and prevents drilling fluid or other contaminants from entering theformation probe assembly 50 during formation testing. More specifically,seal pad 180 may seal against the filter cake that may form on a borehole wall. Typically, the pressure of the formation fluid is less than the pressure of the drilling fluids that are injected into the borehole. A layer of residue from the drilling fluid forms a filter cake on the borehole wall and separates the two pressure areas.Seal pad 180, when extended, may conform its shape to the borehole wall and/or mud cake and forms a seal through which formation fluids can be collected and/or formation properties measured. - In an alternative embodiment of the
seal pad 180, theseal pad 180 may have an internal cavity such that it can retain a volume of fluid. A fluid may be pumped into the seal pad cavity at variable rates such that the pressure in the seal pad cavity may be increased and decreased. Fluids used to fill the seal pad may include hydraulic fluid, saline solution or silicone gel. By way of example, the seal pad may be emptied or unpressured as the probe extends to engage the borehole wall. Depending on the contour of the borehole wall, the seal pad may be pressured by filling the seal pad with fluid, thereby conforming the seal pad surface to the contour of the borehole wall and providing a better seal. - In yet another embodiment of the seal pad, the seal pad may be filled, either before or after engagement with the borehole wall, with an electro-rheological fluid. An electro-rheological fluid may be an insulating oil containing a dispersion of fine solid particles, for example, 5 µm to 50 µm in diameter. Such an electro-rheological fluid is well known in the art. When subjected to an electric field, theses fluids develop an increased shear stress and an increased static yield stress that make them more resistant to flow. This change of fluid properties is evident, for example, as an increase in viscosity, most notably the plastic viscosity, when the electric field is applied. The fluid in the seal pad may effectively become semi-solid. The semi-solid effect is reversed when the fluid is no longer subjected to the electric field. In the absence of the electric field, the electro-rheological fluid that may fill the seal pad becomes less viscous, causing the seal pad to conform to the contour of a borehole wall. Once the seal pad has conformed to the borehole wall, an electric field may be applied to the electro-rheological fluid inside the seal pad, causing an increase in fluid viscosity, a stiffening of the seal pad, and a better seal.
- Still referring to
Figure 6B ,snorkel assembly 98 includes abase portion 125, asnorkel extension 126, and acentral passageway 127 extending throughbase 125 andextension 126.Base portion 125 may include a cylindricalouter surface 122 and inner surface 124.Extension 126 may include a cylindricalouter surface 128 andinner surface 138. Disposed inside the top ofextension 126 is ascreen 100.Screen 100 is a generally tubular member having acentral bore 132 extending between afluid inlet end 131 andfluid outlet end 135.Screen 100 further includes aflange 130 adjacent tofluid inlet end 131 and an internally slottedsegment 133 havingslots 134. Between slottedsegment 133 andoutlet end 135,screen 100 includes threadedsegment 137 for threadedlyengaging snorkel extension 126. - Threaded to the bottom of
base portion 125 ofsnorkel 98 isscraper tube keeper 152 having acircular base portion 154 withflange 153, atubular extension 156 having acentral passageway 155 and acentral aperture 157 for receivingstem extension 107. Just belowscraper tube keeper 152 isretainer ring 159, which provides seated engagement withsnorkel 98 such that the movement ofsnorkel 98 is limited in the retract direction.Scraper tube keeper 152 supportsscraper tube 150 whenscraper tube 150 is in the retracted position shown inFigure 6B .Scraper tube 150 havingcentral passageway 151 extends up fromscraper tube keeper 152 and throughpassageway 127 ofsnorkel 98. Coupled at the top ofscraper tube 150 is scraper orwiper 160.Scraper 160 is threadedly engaged withscraper tube 150 at threadedsegment 161.Scraper 160 is a generally cylindrical member includingscraper plug portion 163,central bore 164 andapertures 166 that are in fluid communication withcentral bore 164.Scraper 160 is disposed withincentral bore 132 ofscreen 100 and may be actuated back and forth (or reciprocal) betweenscreen inlet end 131 andoutlet end 135. Whenscraper tube 150 andscraper 160 are in their retracted positions, as shown inFigure 6B ,apertures 166 are in fluid communication withfluid outlet end 135 ofscreen 100, thereby allowing fluid to pass fromscreen 100, throughscraper bore 164, and intocentral passageway 155 ofscraper tube 150. Scraper orwiper 160 is thus configured to be a moveable or floating scraper. - In an alternative embodiment of the
scraper 160 within thescreen 100, the actuation ofscraper 160 may be a rotational movement around the longitudinal axis ofscraper 160. This rotational movement may be in place of the reciprocal movement, or in addition to the reciprocal movement. - As shown in
Figure 6B , aconnector 176 is disposed inaperture 178 ofprobe collar 12, just beneathinner end 111 ofsleeve 94.Contact lead 175 electrically connectsconnector 176, via a wire, to a contact assembly (not shown) preferably disposed inflange 106 ofstem base portion 105 so that the contact assembly can be in direct contact withbase portion 118 ofpiston 96.Figures 8A-8B show the details ofconnector 176 andcontact assembly 310, with the surrounding structures shown in a more general fashion such that the different parts offormation probe assembly 50a generally correspond with similar parts offormation probe assembly 50 ofFigures 6A-6B . - Referring first to
Figure 8A ,connector 176a is disposed inaperture 178a inprobe collar 12a.Contact lead 175a is coupled towire 300, which extends throughrecess 301 incollar 12a to opening 305 inbase portion 105a ofstem 92a. Fromopening 305,wire 300 extends throughbase portion 105a to acavity 307, wherecontact assembly 310 is disposed. - Referring now to
Figure 8B ,wire 300 leads intocontact assembly 310.Contact assembly 310 generally includeshousing 316 havingaperture 317, aconductive contact body 312 having aflange 314 and acentral bore 319, a strippedend 318 ofwire 300 extending into and soldered to bore 319, anon-conductive spring support 322, and wave springs 324. Theflange 314 ofbody 312 is disposed between the upper portion ofhousing 316 and the lower portion ofspring support 322. Disposed betweenspring support 322 andflange 314 are wave springs 324, which are supported bylower plate 326 andupper plate 328.Springs 324 provide an upward force onflange 314 such thattop surface 313 ofbody 312 extends out ofaperture 317 such thattop surface 313 protrudes out ofcavity 307. Asformation probe assembly 50a is retracting,piston 96a comes into contact with and presses downward onsurface 313 ofbody 312, causingsprings 324 to compress andbottom surface 315 to move downward intospace 324. Whenpiston 96a contacts surface 313 ofbody 312, an electric circuit is completed to ground (not shown) throughpiston 96a, providing a signal to the tool electronics (not shown) thatformation probe assembly 50a has been fully retracted. Afterpiston 96a makes contact withsurface 313 ofbody 312,piston 96a continues to travel until making contact withbase portion 105a ofstem 92a. Heat shrink 320 is shrunk in place overwire 300 for mechanical protection. - Referring now to
Figures 6A and6B ,formation probe assembly 50 is assembled such thatpiston base 118 is permitted to reciprocate alongsurface 113 ofadapter sleeve 94, and pistonouter surface 141 is permitted to reciprocate alongsurface 114. Similarly,snorkel base 125 is disposed withinpiston 96 and is adapted for reciprocal movement along surface 147 whileflange 153 ofscraper tube keeper 152 reciprocates along surface 145.Snorkel extension 126 is adapted for reciprocal movement alongpiston surface 120.Central passageway 127 ofsnorkel 98 is axially aligned withtubular extension 107 ofstem 92,scraper tube keeper 152,scraper tube 150,scraper 160 and withscreen 100.Formation probe assembly 50 is reciprocal between a fully retracted position, as shown inFigure 6A , and a fully extended position, as shown inFigure 6B . Also,scraper tube 150 is reciprocal between a fully retracted position, as shown inFigures 6A-6B , and a fully extended position, as is illustrated by asimilar scraper tube 278 inFigures 7A-7E . Whenscraper tube 150 is fully retracted, fluid may be communicated betweencentral passageway 108 ofextension 107,passageway 155 ofscraper tube keeper 152,passageway 151 ofscraper tube 150, scraper bore 164,scraper apertures 166,screen 100, and the surroundingenvironment 15. - With reference to
Figures 6A and6B , the operation offormation probe assembly 50 will now be described.Formation probe assembly 50 is normally in the retracted position.Formation probe assembly 50 remains retracted when not in use, such as when the drill string is rotating while drilling ifformation probe assembly 50 is used for an MWD application, or when the wireline testing tool is being lowered intoborehole 8 ifformation probe assembly 50 is used for a wireline testing application.Figure 6A showsformation probe assembly 50 in the fully retracted position, except thatscraper tube 150 is shown in the retracted position, andscraper tube 150 is typically extended whenformation probe assembly 50 is in this position, as shown inFigures 7A-7E .Figures 7A-7F will be referred to in describing the operation offormation probe assembly 50 because the structures offormation probe assembly 50 previously described are similar to corresponding parts ofprobe assembly 200 seen inFigures 7A-7F . -
Formation probe assembly 50 typically begins in the retracted position, as shown inFigure 6A . Upon an appropriate command toformation probe assembly 50, a force is applied tobase portion 118 ofpiston 96, preferably by using hydraulic fluid.Piston 96 extends relative to the other portions offormation probe assembly 50 untilretainer ring 159 engagesflange 153 ofscraper tube keeper 152. This position ofpiston 96 relative to snorkelassembly 98 can be seen inFigure 7B . As hydraulic fluid continues to be pumped intohydraulic fluid reservoir 54,piston 96 andsnorkel assembly 98 continue to move upward together.Base portion 118 slides alongadapter sleeve surface 113 untilbase portion 118 comes into contact withshoulder 170. After such contact,formation probe assembly 50 will continue to pressurizereservoir 54 untilreservoir 54 reaches a certain pressure P1. Alternatively, ifseal pad 180 comes into contact with a borehole wall beforebase portion 118 comes into contact withshoulder 170,formation probe assembly 50 will continue to apply pressure to sealpad 180 by pressurizingreservoir 54 up to the pressure P1. The pressure P1 applied toformation probe assembly 50, for example, may be 1,200 p.s.i. - The continued force from the hydraulic fluid in
reservoir 54 causes snorkelassembly 98 to extend such that the outer end ofsnorkel extension 126,inlet end 131 ofscreen 100 and the top ofscraper 160 extend beyondseal pad surface 183 throughseal pad aperture 186. This snorkel extending force must overcome the retract force being applied on the retract side ofsnorkel base portion 125 facingpiston shoulder 172. Previously, the retract force, provided by retractaccumulator 424 and the retract valves, was greater than the extend force, thereby maintainingsnorkel 98 in the retract position. However, the extend force continues to increase until it overcomes the retract force at, for example, 900 p.s.i.Snorkel assembly 98 stops extending outward whensnorkel base portion 125 comes into contact withshoulder 172 ofpiston 96.Scraper tube 150 andscraper 160 are still in the extended position, as is best shown with the snorkel assembly and piston configuration ofFigure 7E . - Alternatively, if
snorkel assembly 98 comes into contact with a borehole wall beforesnorkel base portion 125 comes into contact withshoulder 172 ofpiston 96, continued force from the hydraulic fluid pressure inreservoir 54 is applied up to the previously mentioned maximum pressure. The maximum pressure applied to snorkelassembly 98, for example, may be 1,200 p.s.i. Preferably, the snorkel and seal pad will contact the borehole wall before eitherpiston 96 or snorkel 98 shoulders at full extension. Then, the force applied on the seal pad is reacted bystabilizer 36, or other similar device disposed on ornear probe collar 12. - If, for example,
seal pad 180 had made contact with theborehole wall 16 before being fully extended and pressurized, then sealpad 180 should seal against the mudcake onborehole wall 16 through a combination of pressure and seal pad extrusion. The seal separatessnorkel assembly 98 from the mudcake, drilling fluids and other contaminants outside ofseal pad 180. As the snorkel assembly extends,snorkel extension 126,screen inlet end 131 and the top ofscraper 160 pierce the mudcake that has been sealed off, and preferably go through the entire mudcake layer and intoformation 9. - With
screen 100 andscraper 160 extended, thepiston 96 and snorkel 98 assembly configuration looks similar to the piston and snorkel configuration shown inFigure 7E . While extendingsnorkel extension 126 into the mudcake and formation, contaminants and debris tend to gather onscreen 100 which can affect the sampling of formation fluids. To clear the debris, which may be mudcake or other contaminants from previous sampling procedures,scraper 160 may be retracted aftersnorkel assembly 98 has been extended. A downward retract force is applied toscraper tube 150, preferably by applying a hydraulic fluid force downward onflange 177 ofscraper tube 150. The cavity formed byscraper tube 150 and snorkel surface 124 fills with hydraulic fluid asscraper tube 150 moves downward, untilscraper tube 150 bottoms out onscraper tube keeper 152. Asscraper 160 is drawn withinsnorkel extension 126 during this process,scraper 160 passes throughscreen 100 while also frictionallyengaging screen 100, thereby agitating and removing debris that has gathered onscreen 100. Alternatively, as previously described, debris agitation may be achieved with rotational movement ofscraper 160 about its longitudinal axis withinscreen 100. Whenscraper tube 150 is fully retracted,apertures 166 radially align withoutlet end 135 ofscreen 100 such that fluid communication is possible betweenbore 132 ofscreen 100 andpassageway 151 ofscraper tube 150. Thisscraper 160 action that removes debris is preferably performed as part of theformation probe assembly 50 retract sequence, as described below. - To retract
formation probe assembly 50, forces, or pressure differentials, may be applied to snorkel 98 andpiston 96 in opposite directions relative to the extending forces. Simultaneously, the extending forces may be reduced or ceased to aid in probe retraction. A hydraulic force is applied to snorkelbase portion 125 atshoulder 172 to pushsnorkel assembly 98 down untilflange 153 ofscraper tube keeper 152 sits onretainer ring 159, thereby fully retractingsnorkel assembly 98. Concurrently, a hydraulic force is applied downward onpiston base portion 118 atshoulder 170 untilbase portion 118 bottoms out onstem base portion 105, thereby fully retractingformation probe assembly 50. Whenpiston 96 contacts stembase portion 105, probe retractswitch 176 is triggered as described above, signaling a successful retraction offormation probe assembly 50.Scraper 160 may be extended to its original position at any time during retraction. When the extend pressure on the probe assembly, which provides the retract pressure for the scraper assembly because the probe assembly extend portions are hydraulically coupled to the scraper assembly retract portions, falls below the extend pressure on the scraper assembly,scraper 160 is extended. - Another embodiment of the present invention is shown in
Figures 7A-7F . Probe collar 202 havingflowbore 14a houses telescopingformation probe assembly 200.Probe assembly 200, as compared toformation probe assembly 50, extends to reach a borehole wall that is further displaced from collar 202. Such borehole walls that may be displaced further fromcollar 12 may be found in washed out portions of a well, irregular holes in the well, wells drilled with hole openers or near bit reamers or large wells drilled with bi-center bits. Telescopingprobe assembly 200 is useful in reaching a borehole wall in these types of wells. - Telescoping
probe assembly 200 generally includesstem plate 210,stem 212, a generally cylindrical threadedadapter sleeve 220, anouter piston 230 adapted to reciprocate withinadapter sleeve 220, apiston 240 adapted to reciprocate withinouter piston 230, and asnorkel assembly 260 adapted for reciprocal movement withinpiston 240. Probe collar 202 includes anaperture 204 for receiving telescopingformation probe assembly 200.Cover plate 206 fits over the top ofprobe assembly 200 and retains and protects assembly 200 within probe collar 202.Formation probe assembly 200 is configured to extend throughaperture 208 incover plate 206. - Referring first to
Figure 7A ,adapter sleeve 220 includesinner end 221 near thebottom 207 ofaperture 204.Adapter sleeve 220 is secured withinaperture 204 by threaded engagement with collar 202 atsegment 209. Theouter end 223 ofadapter sleeve 220 extends to be substantially flushed with opening 205 ofaperture 204 formed in collar 202.Outer end 223 includesflanges 225 for engagingcover plate 206.Adapter sleeve 220 includes cylindricalinner surface 227 having reduceddiameter portion 226. Aseal 229 is disposed insurface 226. - Referring next to
Figure 7B ,stem plate 210 includes acircular base portion 213 with anouter flange 214. Extending frombase 213 is ashort extension 216. Extending throughextension 216 andbase 213 is acentral passageway 218 for receiving thelower end 215 ofstem 212 havingcentral passageway 203.Lower end 215 threadedly engagesstem plate passageway 218.Central passageway 218 is in fluid connection with fluid passageway 91 (not shown, but seen schematically inFigure 9 ) that connects to fluid passageway 93 (not shown, but seen schematically inFigure 9 ) leading to other portions oftool 10, includingequalizer valve 60.Stem 212 extends up through the center ofprobe assembly 200. Disposed aboutstem 212 isouter stem 219. Threadedly engaged at the top ofouter stem 219 is outerstem capture screw 222 havingcentral bore 224. - Referring again to
Figure 7B ,outer piston 230 is slidingly retained withinadapter sleeve 220 and generally includes cylindricalouter surface 232 having an increaseddiameter base portion 234. Aseal 235 is disposed in increaseddiameter portion 234.Outer piston 230 also includes cylindricalinner surface 236 having reduceddiameter portions portion 233. Aseal 239 is disposed insurface 237. - Referring now to
Figure 7C ,piston 240 is slidingly retained withinouter piston 230 and generally includes cylindricalouter surface 242 having an increaseddiameter base portion 244. Aseal 245 is disposed in increaseddiameter portion 244. Just belowbase portion 244,piston 240 rests oncapture sleeve 254 which is engaged withbase portion 234 ofouter piston 230.Retainer ring 256 is engaged at the bottom ofcapture sleeve 254 and holds the capture sleeve in position.Piston 240 also includes cylindricalinner surface 246 having reduceddiameter portion 248.Piston 240 further includescentral bore 249 havingbore surface 241 and extending through upper extendingportion 250. - At the top of extending
portion 250 ofpiston 240 is aseal pad 280. As shown inFigures 7A-7F ,seal pad 280 may be donut-shaped with a curvedouter surface 283 andcentral aperture 286. However,seal pad 280 may include numerous other geometries as is known in the art, or, for example, as is seen inU.S. Patent Application No. 10/440,835 entitled "MWD Formation Tester."Base surface 285 ofseal pad 280 may be coupled to askirt 282.Seal pad 280 may be bonded toskirt 282, or otherwise coupled toskirt 282, such as bymolding seal pad 280 ontoskirt 282 such that the seal pad material fills grooves or holes inskirt 282, as can be seen inU.S. Patent Application No. 10/440,835 .Skirt 282 is detachably coupled to extendingportion 250 by way of threaded engagement withsurface 241 ofcentral bore 249, or other means of engagement, such as a pressure fit withcentral bore surface 241. Because the seal pad/skirt combination is detachable from extendingportion 250, it is easily replaced in the field. Alternatively,seal pad 280 may be coupled directly to extendingportion 250 without using a skirt. Other characteristics ofseal pad 280, such as seal pad material and theway seal pad 280 functions, are similar to the previously describedseal pad 180. - Referring now to
Figure 7D , snorkel 260 includes abase portion 262, asnorkel extension 266, and acentral passageway 264 extending throughbase 262 andextension 266.Base portion 262 includes a cylindricalouter surface 268 andinner surface 269.Extension 266 includes a cylindricalouter surface 263 andinner surface 265. Disposed inside the top ofextension 266 is ascreen 290, best shown inFigure 7F .Screen 290 is a generally tubular member having acentral bore 292 extending between afluid inlet end 294 andfluid outlet end 296.Screen 290 further includes aflange 298 adjacent tofluid inlet end 294 and an internally slottedsegment 293 havingslots 295. Between slottedsegment 293 andoutlet end 296,screen 290 includes threadedsegment 297 for threadedlyengaging snorkel extension 266. - Threaded to the bottom of
base portion 262 ofsnorkel 260 isscraper tube keeper 270 having acircular base portion 272 and retainingedge 273, atubular extension 274 having acentral passageway 275 and acentral aperture 271 for receivingouter stem 219.Outer stem 219 includescentral passageway 243. Aretainer ring 277 is radially aligned and engageable with retainingedge 273, which limits the movement ofsnorkel 260 in the retract direction. Aftersnorkel 260 has been extended,retainer ring 277 is disposed belowscraper tube keeper 270 inpiston surface 246, as can be seen inFigure 7E .Scraper tube keeper 270 supportsscraper tube 278 whenscraper tube 278 is in the retracted position shown inFigure 7F , and isolates the hydraulic fluid reservoir formed bytubular extension 274 andsnorkel surface 269.Scraper tube 278 havingcentral passageway 279 is slidingly retained abovescraper tube keeper 270 inpassageway 264 ofsnorkel 260. Coupled at the top ofscraper tube 278 isscraper 288.Scraper 288 is threadedly engaged withscraper tube 278 at threadedsegment 281.Scraper 288 is a generally cylindrical member includingscraper plug portion 284,central bore 287 andapertures 289 that are in fluid communication withcentral bore 287.Scraper 288 is disposed withincentral bore 292 ofscreen 290 and is reciprocal betweenscreen inlet end 294 andoutlet end 296; alternatively, as previously described,scraper 288 may be rotatable withinscreen 290. Whenscraper tube 278 andscraper 288 are in their retracted positions, as shown inFigure 7F ,apertures 289 are in fluid communication withfluid outlet end 296 ofscreen 290, thereby allowing fluid to pass fromscreen 290, throughscraper bore 287, and intocentral passageway 279 ofscraper tube 278. - Referring back to
Figure 7B , a probe retractswitch connector 276 is disposed inaperture 278 of probe collar 202, just beneathinner end 221 ofsleeve 220. The details ofswitch connector 276 are similar to the previously describedswitch 176, above, with reference tofigures 8A-8B . Although not shown, switch andconnector 276 are electrically coupled to a contact assembly disposed instem base portion 213. The contactassembly contacts piston 240 whenpiston 240 is bottomed out onstem base portion 213 indicating to the tool electronics that probeassembly 200 is fully retracted. -
Formation probe assembly 200 is assembled such thatouter piston base 234 is permitted to reciprocate alongsurface 227 ofadapter sleeve 220, andouter piston surface 232 is permitted to reciprocate alongsurface 226. Similarly,piston base portion 244 is permitted to reciprocate along outer pistoninner surface 236, andpiston surface 242 is permitted to reciprocate alongouter piston surface 237.Snorkel base portion 262 is disposed withinpiston 240 and is adapted for reciprocal movement alongsurface 248 while retainingedge 273 ofscraper tube keeper 270 reciprocates betweenretainer ring 277 and decreaseddiameter portion 248.Snorkel extension 266 is adapted for reciprocal movement alongpiston surface 241.Central passageway 264 ofsnorkel 260 is axially aligned withstem 212,outer stem 219,scraper tube keeper 270,scraper tube 278,scraper 288 and withscreen 290.Formation probe assembly 200 is reciprocal between a fully retracted position, as shown inFigure 7A , and a fully extended position, as shown inFigure 7F . Also,scraper tube 278 is reciprocal between a fully extended position, as shown inFigures 7A-7E , and a fully retracted position, as is illustrated inFigure 7F . Whenscraper tube 278 is fully retracted, fluid may be communicated betweencentral passageway 203 ofstem 212,passageway 243 ofouter stem 219,passageway 275 ofscraper tube keeper 270,passageway 279 ofscraper tube 278, bore 287 ofscraper 288,scraper apertures 289,screen 290, and the surroundingenvironment 15. - With reference to
Figures 7A-7F , the operation offormation probe assembly 200 will now be described.Formation probe assembly 200 typically begins in the retracted position, as shown inFigure 7A .Assembly 200 remains retracted when not in use, such as when the drill string is rotating while drilling ifassembly 200 is used for an MWD application, or when the wireline testing tool is being lowered intoborehole 8 ifassembly 200 is used for a wireline testing application.Figure 7A shows assembly 200 in the fully retracted position, withscraper tube 278 in the extended position. - Upon an appropriate command to probe
assembly 200, a force is applied tobase portion 234 ofouter piston 230, preferably by using hydraulic fluid.Outer piston 230 raises relative toadapter sleeve 220, with outer piston base portion sliding alongsleeve surface 227.Retainer ring 256 and capturesleeve 254force piston 240 upward along withouter piston 230 by pressing onpiston base portion 244. As seen inFigure 7B , snorkel 260 remains seated onstem plate 210 whileouter piston 230 andpiston 240 begin to rise, untilretainer ring 277contacts retaining edge 273 ofscraper tube keeper 270. At this point, the upward hydraulic force continues to be applied to the reciprocal parts ofassembly 200, andfluid reservoir 334 enlarges and fills until outerpiston base portion 234 seats onadapter sleeve shoulder 332, as shown inFigure 7C . Then hydraulic fluid is directed intoreservoir 336, causingpiston 240 and snorkel 260 to extend out, withpiston base portion 244 sliding alongouter piston surface 236. Finally,piston base portion 244 seats onouter piston shoulder 342, as shown inFigure 7D . Once again, typically, snorkel 260 and seal pad 280 (Figure 7C ) contact the borehole wall prior to reaching full extension, as previously described. The tool stabilizer, or other such device, will react the probe extension force. - Before reaching the position shown in
Figure 7D ,seal pad 280 is preferably engaged with the borehole wall (not shown). To form a seal withseal pad 280,probe assembly 200 will continue to pressurize thereservoirs seal pad 180 comes into contact with the borehole wall beforeprobe assembly 200 is fully extended,probe assembly 200 will continue to apply pressure to sealpad 280 up to the previously mentioned maximum pressure. The maximum pressure applied byprobe assembly 200, for example, may be 1,200 p.s.i. - As hydraulic fluid continues to be pumped through
reservoirs surfaces reservoir 338 and this snorkel extend force increases. This snorkel extending force must overcome the retract force being applied on the retract side ofsnorkel base portion 262 facingpiston shoulder 352. Previously, the retract force, provided by retractaccumulator 424 and the retract valves, was greater than the extend force, thereby maintainingsnorkel 260 in the retract position. However, the extend force continues to increase until it overcomes the retract force at, for example, 900 p.s.i.Snorkel base portion 262 finally seats onpiston shoulder 352, as shown inFigure 7E .Snorkel 260 has extended such that the outer end ofsnorkel extension 266,inlet end 294 ofscreen 290 and the top ofscraper 288 extend beyondseal pad surface 283 throughseal pad aperture 286.Scraper tube 278 andscraper 288 are still in the extended position, as seen inFigure 7E . Ifseal pad 280 is engaged with the borehole wall,snorkel extension 266,screen inlet end 294 and the top ofscraper 288 pierce the mudcake that has been sealed off, and preferably go through the entire mudcake layer and intoformation 9. - As previously described, extending
snorkel extension 266 into the mudcake and formation causes contaminants and debris to gather onscreen 290, which can affect the sampling of formation fluids. Floatingscraper 288 is used to clear the debris in a similar fashion to that described with respect toformation probe assembly 50. A downward force is applied toscraper tube 278, preferably by applying a hydraulic fluid force downward onflange 372 ofscraper tube 278. The cavity formed byscraper tube 278 andinner snorkel surface 269 fills with hydraulic fluid asscraper tube 278 moves downward, untiltube flange 372 seats onscraper tube keeper 270. Asscraper 288 is drawn withinsnorkel extension 266 during this process,scraper 288 passes throughscreen 290, agitating and removing debris that has gathered onscreen 290 through frictional engagement betweenscraper 288 andscreen 290, as previously described. Also previously described was an alternative embodiment including arotating screen 290, equally applicable here. Whenscraper tube 278 is fully retracted,apertures 289 radially align withscreen outlet end 296 such that fluid communication is possible between screen bore 292 andpassageway 279 ofscraper tube 278. Thisscraper 288 action that removes debris is preferably performed as part of theformation probe assembly 200 retract sequence, as described below. - To retract
probe assembly 200, forces, or pressure differentials, may be applied to probe assembly 200 in opposite directions relative to the extending forces. Simultaneously, the extending forces may be reduced or ceased to aid in probe retraction. First, and preferably, a pressure differential is applied acrossflange 372 ofscraper tube 278 by increasing the hydraulic fluid pressure on the bottom offlange 372. This extendsscraper tube 278 untilscraper 288 is fully extended once again, wipingscreen 290 clean asscraper 288 passes through it. Next, a hydraulic force is applied to snorkelbase portion 262 atshoulder 352 to pushsnorkel assembly 260 down until retainingedge 273 ofscraper tube keeper 270 sits onretainer ring 277, thereby fully retractingsnorkel assembly 260. Next, a hydraulic force is applied downward onpiston base portion 244 atshoulder 342 untilbase portion 244 seats oncapture sleeve 254 andretainer ring 256 adjacent outerpiston base portion 234. From this position, a hydraulic fluid is inserted atadapter sleeve shoulder 332 onto outerpiston base portion 234 to forceouter piston 230 downward.Outer piston 230 then seats onbottom 207 ofaperture 204, and thepiston 240/snorkel 260 assembly seats onstem plate 210, thereby fully retractingprobe assembly 200. Whenpiston 240 contacts stemplate 210, probe retractswitch 276 is triggered as described above, signaling a successful retraction ofassembly 200. - It is noted that
formation probe assembly 50 may only extend the outer end ofpiston extending portion 119 past the outer end ofsleeve 94 a distance that is less than the length ofpiston 96. The length ofpiston 96 is defined as the distance between the uppermost end of extendingportion 119 and the lowermost end ofbase portion 118. In comparison,probe assembly 200 may extend the outer end of pistonupper portion 250 past the outer end of sleeve 220 a distance that exceeds the length ofpiston 240. Therefore, the telescoping feature ofprobe assembly 200, i.e., theconcentric pistons seal pad 280 to engage a borehole wall that is significantly further from collar 202 than the length ofpiston 240. - Referring now to
Figure 14 , an example of how the probe assemblies may be used to test a formation will be described. Thetest sequence 700 may begin (box 702) upon a command to thetool 10 from the surface of the borehole, for example, or from embedded tool software. In a first embodiment,piston 96 andseal pad 180 may be extended (box 704). In a further embodiment,piston 230 may be extended (box 703) to provide the telescopic effect previously described. The borehole wall is contacted by seal pad 180 (box 706). Next, avolume surrounding snorkel 98 is sealed (box 708). In a further embodiment,seal pad 180 may be filled with a fluid (box 707), as previously described. Continuing with thesequence 700, snorkel 98 may be extended (box 710), and the borehole wall contacted by snorkel 98 (box 712).Scraper 160 may now be retracted (box 714), causing agitation and removal of contaminants fromsnorkel 98. A formation property may then be measured (box 716). In a further embodiment, contaminants may be filtered (box 715), such as by ascreen 100. After measuring a formation property, snorkel 98 is retracted (box 718),piston 96 andseal pad 180 are retracted (box 720), andscraper 160 is extended (box 722). The extension ofscraper 160 may also serve to remove contaminants fromsnorkel 98.Sequence 700 ends (box 724) with a formation property having been measured for uses further described herein. - In an alternative embodiment of
tool 10,formation probe assemblies Figure 3B ,formation probe assembly 50 may instead be disposed inblade 37 ofstabilizer 36.Equalizer valve 60,shutoff valve 74 and draw downpistons Figure 3B , although it is preferred that they be in closer proximity toformation probe assembly 50, and therefore may be moved closer tostabilizer 36. Locatingformation probe assemblies stabilizer blade 37 allows the assemblies to be placed closer to the borehole wall while still mounted in a robust portion of the tool. Further, the other blades ofstabilizer 36 may be used to back upformation probe assemblies - Even if
formation probe assemblies stabilizer 36, the blades ofstabilizer 36 are preferably used to back up the extendingformation probe assemblies U.S. Patent Application Serial No. 10/440,593, filed May 19, 2003 - With respect to any of the probe assembly embodiments described above, a probe assembly position indicator may be included in the probe assembly to measure the distance that the probe assembly has extended from its fully retracted position. Numerous sensors may be used to detect the position of the probe assembly as it extends. In one embodiment, the probe assembly position indicator may be a measure of the volume of hydraulic fluid used to extend the probe assembly. If the probe assembly is configured to use hydraulic fluid and pressure differentials to extend, as is described in the embodiments above, the volume of fluid pumped into the probe assembly may be measured. With known diameters for the adapter sleeves and pistons, the distance that the pistons have extended may be calculated using the volume of fluid that has been pumped into the probe assembly. To make this measurement more accurate, certain characteristics of the probe assembly may be accounted for, such as seal pad compression as it compresses against the borehole wall.
- In another embodiment of the probe assembly position indicator, an optical or acoustic sensor may be disposed in the probe assembly, such as in an aperture formed in the
piston surface 141 offormation probe assembly 50, orpiston surface 242 ofprobe assembly 200. The optical or acoustic sensor may measure the distance the piston moves from a known reference point, such as the piston position when the probe assembly is fully retracted. Such devices are well known to one skilled in the art. - In yet another embodiment, a potentiometer, resistance-measuring device or other such device well known to one skilled in the art may be used to detect movement of the reciprocating portions of the probe assemblies through electrical means. The potentiometer or resistance-measuring device may measure voltage or resistance, and such information can be used to calculate distance.
- The distance measurement gathered from the probe position indicator may be used for numerous purposes. For example, the borehole caliper may be calculated using this measurement, thereby obtaining an accurate measurement of the borehole diameter. Alternatively, multiple probes may be spaced radially around the drill string or wireline instrument, and measurements may be taken with the multiple probes to obtain borehole diameter and shape. Having an accurate borehole caliper measurement allows the driller to know where borehole breakout or collapse may be occurring. The caliper measurement may also be used to help correct formation evaluation sensors. For example, resistivity measurements are affected by borehole size. Neutron corrections applied to a neutron tool are also affected, as well as density corrections applied to a density tool. Other sensor tools may also be affected. An accurate borehole caliper measurement assists in correcting these tools, as well as any other drilling, production and completion process that requires borehole size characteristics, such as cementing.
- In another embodiment, the probe position indicator may be used to correct for probe flow line volume changes. Flow lines, such as
flow lines Figures 6A ,6B and9 , are susceptible to volume changes as the probe seal pad compresses and decompresses. Particularly, when the seal pad is engaged with the borehole wall and a formation test is in progress, the pressure from drawing down the formation fluids causes the seal pad to compress and the flow line volume to increase. The flow line volume is used in several formation calculations, such as mobility; permeability may then be calculated using formation fluid viscosity and density. To correct for this volume change and obtain an accurate flow line volume measurement, probe positioning may be used. Further, although the full flow line volume is known, if the probe does not fully extend before engaging the borehole wall, only a portion of the flow line volume is used and that quantity may not be known. Therefore, the probe position may be used to correct for the portion of the flow line volume that is not being used. - The embodiments of the position indicator described above may also be applied to the draw down piston assemblies, described in more detail below, for knowing where in the cylinder the draw down piston is located, and how the piston is moving. Volume and diameter calculations may be used to obtain distance moved, or sensors may be used as described above. Thus, the exact distance the piston has moved may be obtained, rather than relying on the volume of fluid used to actuate the piston as an indication of distance moved. Further, the steadiness of the draw down may be obtained from the position indicator. The rate may be calculated from the distance measured, and the steadiness of the rate may be used to correct other measurements.
- For example, to gain a better understanding of the formation's permeability or the bubble point of the formation fluids, a reference pressure may be chosen to draw down to, and then the distance the draw down piston moved before that reference pressure was reached may be measured by the draw down piston position indicator. If the bubble point is reached, the distance the piston moved may be recorded and sent to the surface, or to the software in the tool, so that the piston may be commanded to move less and thereby avoid the bubble point.
- Sensors intended for other purposes may also be disposed in the probe assemblies. For example, a temperature sensor, known to one skilled in the art, may be disposed on the probe assembly for taking annulus or formation temperature. In one embodiment, the temperature sensor may be placed in the
snorkel extensions - Referring back to
Figures 3B and5 , it can be seen thatprobe collar 12 also houses draw downpiston assemblies shutoff valve assembly 74. Referring now toFigure 11 , draw downpiston assembly 70 generally includesannular seal 502, piston 506, plunger 510 andendcap 508. Piston 506 is slidingly received incylinder 504 and plunger 510, which is integral with and extends from piston 506, is slidingly received in cylinder 514. InFigure 11 , piston 506 is in its drawn down position, but is typically biased to its uppermost or shouldered position atshoulder 516. A bias spring (not shown) biases piston 506 to the shouldered position, and is disposed inlower cylinder portion 504b between piston 506 andendcap 508. Separate hydraulic lines (not shown) interconnect withcylinder 504 above and below piston 506 inportions cylinder 504 as described more fully below. Plunger 510 is slidingly disposed in cylinder 514 coaxial withcylinder 504.Cylinder 512 is the upper portion of cylinder 514 that is in fluid communication with the longitudinal passageway 93 (seen schematically inFigure 9 ) that interconnects with draw downshutoff valve assembly 74, draw downpiston 72,formation probe assembly equalizer valve 60.Cylinder 512 is flooded with drilling fluid via its interconnection withpassageway 93. Cylinder 514 is filled with hydraulic fluid beneathseal 513 via its interconnection withhydraulic circuit 400. -
Endcap 508 houses a contact switch (not shown) having a contact that faces toward piston 506. Awire 515 is coupled to the contact switch. Aplunger 511 is disposed in piston 506. When drawdown ofpiston assembly 70 is complete, as shown inFigure 11 , piston 506 actuates the contact switch by causingplunger 511 to engage the contact of the contact switch, which causeswire 515 to couple to system ground via the contact switch toplunger 511 to piston 506 toendcap 508 which is in communication with system ground (not shown). - Referring to
Figure 12 , a second draw downpiston assembly 72 is shown. Draw downpiston 72 is similar topiston 70, with the most notable difference being that the draw down volume is greater and the assembly does not include a bias spring. Draw downpiston assembly 72 generally includesannular seal 532,piston 536,plunger 540 andendcap 538.Piston 536 is slidingly received incylinder 534 andplunger 540, which is integral with and extends frompiston 536, is slidingly received incylinder 544.Plunger 540 andcylinder 544 have greater diameters than the corresponding portions ofpiston 70. InFigure 12 ,piston 536 is in its drawn down position, but is typically maintained at its uppermost or shouldered position atshoulder 546 by hydraulic force. Separate hydraulic lines (not shown) interconnect withcylinder 534 above and belowpiston 536 inportions piston 536 either up or down withincylinder 534 as described more fully below.Plunger 540 is slidingly disposed incylinder 544 coaxial withcylinder 534.Cylinder 542 is the upper portion ofcylinder 544 that is in fluid communcation with the longitudinal passageway 93 (seen schematically inFigure 9 ) that interconnects with draw downshutoff valve assembly 74, draw downpiston 70,formation probe assembly equalizer valve 60.Cylinder 542 is flooded with drilling fluid via its interconnection withpassageway 93.Cylinder 544 is filled with hydraulic fluid beneathseal 543 via its interconnection withhydraulic circuit 400. -
Endcap 538 houses acontact switch 548 having acontact 550 that faces towardpiston 536. Awire 545 is coupled to contactswitch 548. Aplunger 541 is disposed inpiston 536. When drawdown ofpiston assembly 72 is complete, as shown inFigure 12 ,piston 536 actuatescontact switch 548 by causingplunger 541 to engagecontact 550, which causeswire 545 to couple to system ground viacontact switch 548 toplunger 541 topiston 536 toendcap 538 which is in communication with system ground (not shown). - It will be understood that the draw down pistons may vary in size such that their volumes vary. The pistons may also be configured to draw down at varying pressures. The embodiment just described includes two draw down piston assemblies, but the formation tester tool may include more or less than two.
- The
hydraulic circuit 400 used to operateformation probe assemblies equalizer valve 60 and draw downpistons Figure 9 . A microprocessor-basedcontroller 402 is electrically coupled to all of the controlled elements in thehydraulic circuit 400 illustrated inFigure 9 , although the electrical connections to such elements are conventional and are not illustrated other than schematically.Controller 402 is located inelectronics module 20, shown inFigure 2A , although it could be housed elsewhere intool 10 orbottom hole assembly 6.Controller 402 detects the control signals transmitted from amaster controller 401 housed in theMWD sub 13 of thebottom hole assembly 6 which, in turn, receives instructions transmitted from the surface via mud pulse telemetry, or any of various other conventional means for transmitting signals to downhole tools. - When
controller 402 receives a command to initiate formation testing, the drill string has stopped rotating iftool 10 is disposed on a drill sting. As shown inFigure 9 ,motor 404 is coupled to pump 406 which draws hydraulic fluid out ofhydraulic reservoir 408 through aserviceable filter 410. As will be understood, thepump 406 directs hydraulic fluid intohydraulic circuit 400 that includesformation probe assembly 50, 200 (either can be used interchangeably),equalizer valve 60, draw downpistons solenoid valves formation probe assembly 50, the hydraulic circuit described may be used to operateformation probe assembly 50 orprobe assembly 200. - The operation of
formation tester 10 is best understood with reference toFigure 9 in conjunction withFigures 6A-6B ,7A-F ,11 and 12 . In response to an electrical control signal,controller 402 energizes retractsolenoid valve 412 andvalve 414, and startsmotor 404. Pump 406 then begins to pressurizehydraulic circuit 400 and, more particularly, charges probe retractaccumulator 424. The act of chargingaccumulator 424 also ensures that theformation probe assembly 50 is retracted, theequalizer valve 60 is open and that draw downpistons Figures 11 and 12 . When the pressure insystem 400 reaches a predetermined value, such as 1800 p.s.i. as sensed bypressure transducer 426a, controller 402 (which continuously monitors pressure in the system) energizes extendsolenoid valve 416 which causesformation probe assembly 50 to begin to extend toward theborehole wall 16. Concurrently,check valve 428 andrelief valve 429 seal the probe retractaccumulator 424 at a pressure charge of between approximately 500 to 1250 p.s.i.Solenoid valve 412 is still energized. -
Formation probe assembly 50 extends, as previously described, from the position shown inFigure 6A to a position before full extension as shown inFigure 6B (except with snorkel still retracted), whereseal pad 180 engages themud cake 49 onborehole wall 16. At this point, retractsolenoid valve 412 is de-energized, thereby allowingsnorkel 98 to be extended andscraper 160 to be retracted. With hydraulic pressure continuing to be supplied to the extend side ofpiston 96 and snorkel 98 forformation probe assembly 50, the snorkel may then penetrate the mud cake and the scraper retracted, as shown inFigure 6B (andFigures 7E-7F for assembly 200). The outward extensions ofpistons 96 and snorkel 98 continue untilseal pad 180 engages theborehole wall 16, as previously described with regard toformation probe assembly 50. This combined motion continues until the pressure pushing against the extend side ofpiston 96 andsnorkel 98 reaches a pre-determined magnitude, for example 1,200 p.s.i., controlled byrelief valve 417, causingseal pad 180 to be squeezed. At this point, a second stage of expansion takes place withsnorkel 98 then moving within thecylinders 120 inpiston 96 to penetrate themud cake 49 on theborehole wall 16 and to receive formation fluids or take other measurements. -
De-energizing solenoid valve 412 also closesequalizer valve 60, thereby isolatingfluid passageway 93 from the annulus. In this manner,valve 412 ensures thatvalve 60 closes only after the seal pad 140 has entered contact withmud cake 49 which lines boreholewall 16.Passageway 93, now closed to theannulus 15, is in fluid communication withcylinders cylinders 514, 544 in draw downpiston assemblies Figures 11 and 12 . - With extend
solenoid valve 416 still energized, and thehydraulic circuit 400 at approximately 1,200 p.s.i., probe extendaccumulator 430 has been charged andcontroller 402 energizessolenoid valve 414. Energizingvalve 414 closes off the extend section of the hydraulic circuit, thereby maintaining the extend section at approximately 1,200 p.s.i. and allowing drawdown to begin. Withvalve 414 energized, pressure can be added to the draw down circuit, which generally includes draw downaccumulator 432,solenoid valves piston assemblies -
Controller 402 now energizessolenoid valve 420 which permits pressurized fluid to enterportion 504a ofcylinder 504 causing draw downpiston 70 to retract. When that occurs, plunger 510 moves within cylinder 514 such that the volume offluid passageway 93 increases by the volume of the area of the plunger 510 times the length of its stroke along cylinder 514. The volume ofcylinder 512 is increased by this movement, thereby increasing the volume of fluid inpassageway 93. Preferably, these elements are sized such that the volume offluid passageway 93 is increased by preferably 30 cc maximum as a result ofpiston 70 being retracted. - If draw down
piston 70 is to be stopped due to, for example, the need for only a partial draw down or an unsuccessful partial draw down,controller 402 may energizesolenoid valve 418 to pressurize the draw downshutoff valve assembly 74.Pressurizing valve assembly 74 causes draw downpiston 70 to cease drawing down formation fluids. Now,valve assembly 74 and draw downpiston 70 have been pressured up to approximately 1,800 p.s.i. This ensures thatshutoff valve assembly 74 holds draw downpiston 70 in its drawn down, or partially drawn down, position such that the drawn formation fluids are retained and not inadvertently expelled. - When it is desired to continue drawing down with draw down
piston 70,solenoid valve 418 can be de-energized, thereby turningshutoff valve 74 off. Draw down with draw downpiston 70 then commences until the volume of cylinder 514 filled. The draw down of draw downpiston 70 may continue to be interrupted usingvalves -
Controller 402 may be used to command draw downpiston 70 to draw down fluids at differing rates and volumes. For example, draw downpiston 70 may be commanded to draw down fluids at 1cc per second for 10 cc and then wait 5 minutes. If the results of this test are unsatisfactory, a downlink signal may be sent using mud pulse telemetry, or another form of downhole communication,programming controller 402 to commandpiston 70 to now draw down fluids at 2cc per second for 20 cc and then wait 10 minutes, for example. The first test may be interrupted, parameters changed and the test may be restarted with the new parameters that have been sent from the surface to the tool. These parameter changes may be made whileformation probe assembly 50 is extended. - While draw down
piston 70 is stopped,controller 402 may energizesolenoid valve 422 which permits pressurized fluid to enterportion 534a ofcylinder 534 causing draw downpiston 72 to retract. When that occurs,plunger 540 moves withincylinder 534 such that the volume offluid passageway 93 increases by the volume of the area of theplunger 540 times the length of its stroke alongcylinder 544. The volume ofcylinder 542 is increased by this movement, thereby increasing the volume of fluid inpassageway 93. Preferably, these elements are sized such that the volume offluid passageway 93 is increased by 50 cc as a result ofpiston 72 being retracted. Preferably, draw downpiston 72 does not have the stop and start feature ofpiston 70, and is able to draw down more fluids at a faster rate. Thus, draw downpiston 72 may be configured to draw down fluids at rates of 3.8 or 7.7 cc per second, for example. However, it should be understood that eitherpiston piston 72 may also be configured to have the stop and start feature via the shutoff valve assembly. Thus,hydraulic circuit 400 may be configured to operatemultiple pistons 70 and/ormultiple pistons 72. Also,pistons - The ability to control draw down
pistons - Maintaining clean flow lines is important to protecting instruments in the testing tool, and to maintaining the integrity of the formation tests by purging old fluids left in the flow lines. Thus, in another embodiment for keeping the flow lines clean, a mechanical filter may be placed in the flow lines, such as anywhere along
flow lines Figures 6A ,6B and9 . Alternatively, the flow lines may be purged by openingequalizer valve 60, pumping out fluids present in the flow lines, then closingequalizer valve 60 in preparation of another draw down sequence. - As draw down
piston 70 is actuated, 30 cc of formation fluid will thus be drawn throughcentral passageway 127 ofsnorkel 98 and throughscreen 100. The movement of draw downpiston 70 within itscylinder 504 lowers the pressure inclosed passageway 93 to a pressure below the formation pressure, such that formation fluid is drawn throughscreen 100 and intoapertures 166, throughsnorkel 98, then throughstem passageway 108 topassageway 91 that is in fluid communication withpassageway 93 and part of the same closed fluid system. In total, fluid chambers 93 (which include the volume of various interconnected fluid passageways, including passageways information probe assembly 50,passageways pistons piston 72 is also activated, this volume should increase approximately 30 cc, up to approximately 90 cc total. Drilling mud inannulus 15 is not drawn intosnorkel 98 becauseseal pad 180 seals against the mud cake.Snorkel 98 serves as a conduit through which the formation fluid may pass and the pressure of the formation fluid may be measured inpassageway 93 whileseal pad 180 serves as a seal to prevent annular fluids from entering thesnorkel 98 and invalidating the formation pressure measurement. - Referring momentarily to
Figure 6B , formation fluid is drawn first into thecentral bore 132 ofscreen 100. It then passes throughslots 134 in screen slottedsegment 133 such that particles in the fluid are filtered from the flow and are not drawn intopassageway 93. The formation fluid then passes between the outer surface ofscreen 100 and the inner surface ofsnorkel extension 126 where it next passes throughoutlet end 135,apertures 166 inscraper 160,scraper tube 150 and into thecentral passageway 108 ofstem 92. - Screen 100 (and
screen 290 of assembly 200) may be optimized for particular applications. For example, if prior knowledge of the formation is obtained, then the screen can be tailored to the type of rock or sediment that is present in the formation. One type of adjustable screen is a gravel-packed screen, which may be used instead of or in conjunction with the slottedscreen 100. Generally, a gravel-packed screen is two longitudinal, cylindrical screens of different diameters. The screens are disposed concentrically and the annulus is filled with gravel pack sieve, or a known sand size. - Despite the type of formation encountered, the gravel pack may be tailored to have a 10-to-1 ratio of formation sand size to gravel pack size, which is the preferable formation particle size to gravel particle size ratio. With this ratio, it is expected that the gravel pack screen will have the ability to screen formation particles up to 1/10th the size of the nominal formation particle diameter size encountered. With this embodiment, the gravel pack sand size can be tailored to the specific intended application.
- In yet another embodiment, the
screens Figures 6B ,7F may be optimized by adjusting the size and number of slits required for a particular application. The slits, or slots, are illustrated schematically as internally slottedsegment 133 havingslots 134 inFigure 6B , and internally slottedsegment 293 havingslots 295. The size and number of slits can be tailored to the particular formation expected to be intersected, and the nominal sand particle size of the produced sand. For example, more slits with smaller openings may be used for smaller nominal formation particle size. - In a further embodiment, the above mentioned adjustment of slot size may be accomplished real-time. In the previous embodiment, the slot size is set upon deployment of
tool 10 into the borehole. The slot size remains unchanged whiletool 10 is deployed. The slot size may be adjusted at the surface of the borehole by replacingscreens tool 10 is deployed downhole. In the current embodiment, detection of the type of formation actually intersected may be achieved via the various apparatus and methods disclosed herein. If the detected formation value, such as particle size, differs from a predetermined value, the slot size may be adjusted without trippingtool 10 out of the borehole. A command may be given from the surface of the borehole, or fromtool 10, and slot size may be adjusted by moving two concentrically disposed slotted cylindrical members relative to each other, for example, or by adjusting shutter mechanisms adj acent the slots. - Referring again to
Figure 9 , withseal pad 180 sealed against the borehole wall,check valve 434 maintains the desired pressure acting againstpiston 96 andsnorkel 98 to maintain the proper seal ofseal pad 180. Additionally, becauseprobe seal accumulator 430 is fully charged, shouldtool 10 move during drawdown, additional hydraulic fluid volume may be supplied topiston 96 andsnorkel 98 to ensure thatseal pad 180 remains tightly sealed against the borehole wall. In addition, should theborehole wall 16 move in the vicinity ofseal pad 180, theprobe seal accumulator 430 will supply additional hydraulic fluid volume topiston 96 andsnorkel 98 to ensure thatseal pad 180 remains tightly sealed against theborehole wall 16. Withoutaccumulator 430 incircuit 400, movement of thetool 10 orborehole wall 16, and thus offormation probe assembly 50, could result in a loss of seal atseal pad 180 and a failure of the formation test. - With the
drawdown pistons system 93, the pressure will stabilize enablingpressure transducers 426b,c to sense and measure formation fluid pressure. The measured pressure is transmitted to thecontroller 402 in the electronic section where the information is stored in memory and, alternatively or additionally, is communicated to themaster controller 401 in theMWD tool 13 belowformation tester 10 where it can be transmitted to the surface via mud pulse telemetry or by any other conventional telemetry means. - When drawdown is completed,
pistons contact switch 550, for example, is actuatedcontroller 402 responds by shutting downmotor 404 and pump 406 for energy conservation.Check valve 436 traps the hydraulic pressure and maintainspistons pistons drawdown accumulator 432 will provide the necessary fluid volume to compensate for any such leakage and thereby maintain sufficient force to retainpistons - During this interval,
controller 402 continuously monitors the pressure influid passageway 93 viapressure transducers 426 b, c. When the measured pressure stabilizes, or after a predetermined time interval,controller 402 de-energizes extendsolenoid valve 416. When this occurs, pressure is removed from the close side ofequalizer valve 60 and from the extend side ofprobe piston 96.Equalizer valve 60 will return to its normally open state and probe retractaccumulator 424 will causepiston 96 andsnorkel 98 to retract, such thatseal pad 180 becomes disengaged with the borehole wall. Thereafter,controller 402 again powers motor 404 to drivepump 406 and again energizessolenoid valve 412. This step ensures thatpiston 96 and snorkel 98 have fully retracted and that theequalizer valve 60 is opened. Given this arrangement, the formation tool has a redundant probe retract mechanism. Active retract force is provided by thepump 406. A passive retract force is supplied by probe retractaccumulator 424 that is capable of retracting the probe even in the event that power is lost. It is preferred thataccumulator 424 be charged at the surface before being employed downhole to provide pressure to retain the piston and snorkel inhousing 12. - It will be understood that the
equalizer valve 60 may be opened in a similar manner at other times during probe engagement with the borehole wall. If the probe seal pad is in danger of becoming stuck on the borehole wall, the suction may be broken by openingequalizer valve 60 as described above. - After a predetermined pressure, for example 1800 p.s.i., is sensed by
pressure transducer 426a and communicated to controller 402 (indicating that the equalizer valve is open and that the piston and snorkel are fully retracted),controller 402 de-energizes solenoidvalves sides drawdown pistons solenoid valve 412 remaining energized, positive pressure is applied tosides drawdown pistons pistons Controller 402 monitors the pressure viapressure transducer 426a and when a predetermined pressure is reached,controller 402 determines thatpistons motor 404 and pump 406 andde-energizes solenoid valve 412. With all solenoid valves returned to their original positions and withmotor 404 off,tool 10 is back in its original condition. - The
hydraulic circuit 400, as described and illustrated inFigure 9 , may also act as a regenerative circuit while extending the probe assembly. With both retractvalve 412 and extendvalve 416 energized or actuated, as described above, and the difference in areas between the smaller area on the retract side of the probe piston, such aspiston 96 orpiston 240, and the larger area on the extend side of the piston, there is a net effect of extending the probe assembly. As the piston continues to extend with retract valve still open, there is a back flow of hydraulic fluid through retractvalve 412 due to the lack of a check valve behind retractvalve 412. This relatively unimpeded back flow path leads into the pressurized hydraulic fluid flowing into extendvalve 416, adding to the pressure on the extend side of the circuit and increasing the rate at which the probe may extend. - During extension of the probe assembly, using
hydraulic circuit 400, it can be seen that the total volume of hydraulic fluid required to be displaced bypump 406, and hence the number of revolutions ofmotor 404, is reduced compared to a non-regenerative circuit. The regenerative nature ofcircuit 400 also allows the moveable wiper or scraper, such asscraper 160, to remain extended during extension of the probe assembly, especially as the snorkel assembly is penetrating the mudcake and formation and there is an extra force pushing back on the moveable scraper. As can be seen inFigures 6A ,6B and7A-7F , the area of the extend side of the scraper assembly, for example, the bottom offlange 372 ofscraper tube 278 inFigure 7F , is greater than the area of the retract side, or the upper side offlange 372. Thus, with bothvalves scraper tube 278, as previously described. - Further, as mentioned before, the regeneration of pressure in
circuit 400 allows faster extension of the probe assembly. In addition, the regenerated pressure assists with control of equalizer valve actuation. - A hydraulic
reservoir accumulator assembly 600 is disposed inprobe collar 12 as shown inFigure 10I .Reservoir accumulator assembly 600 maintains a pressure above the annulus or surrounding environment pressure in thecomplete tool 10 hydraulic system. This condition in the hydraulic system compensates for pressure and temperature changes in the tool. Also, the pressure provided fromassembly 600 causes pump 406 (Figure 9 ) to begin operating from the annulus pressure, thereby reducing the work load that would be required from startingpump 406 at atmospheric pressure. Thus,accumulator assembly 600 may be used to communicate annulus pressure into the tool's hydraulic system. As will be seen below,assembly 600 is self contained and easily field replaceable. -
Assembly 600 generally includes abody 602 having atop surface 632, bottom surface 634 (Figure 10C ) andendcap 604 atend 606, several lockingwings 608 anddrilling fluid apertures end 622.Top surface 632 includes additionalfluid apertures screen 639 as illustrated inFigure 10F .Screen 639 is held in place by retainingring 637, and prevents large particles in the drilling fluid from entering the cylinders and interfering with the reciprocation of the pistons.Endcap 604 includes apressure plug 638 for connectingassembly 600 to probecollar 12, which helps to lockassembly 600 into place as illustrated inFigure 10H .Endcap 604 also includes hydraulicfluid check valves assembly 600 and the tool hydraulic system whenassembly 600 is removed fromcollar 12. - Referring briefly to
Figure 10F , it can be seen that the inside ofassembly 600 is split into twocylinders Figure 10C illustratescylinder 626 retaining apiston 636 which separatescylinder 626 intohydraulic fluid portion 626a anddrilling fluid portion 626b.Piston 636 is reciprocal between the position shown inFigure 10C and the position ofpiston 656 shown inFigure 10D .Spring 624 is retained incylinder portion 626b betweenpiston 636 and end 622.Spring 624 extendspast piston end 636b aroundpiston 636 and seats on increasedpiston diameter portion 633. Increaseddiameter portion 633 is similar to increaseddiameter portion 653 ofpiston 656, illustrated inFigure 10G . Atend 622,aperture 620 allows drilling fluids to entercylinder portion 626b and exert the surrounding annulus pressure onside 636b ofpiston 636. Becausespring 624 also exerts a force onside 636b, the pressure of hydraulic fluid incylinder portion 626a is greater than the annulus pressure. The pressure of the hydraulic fluid incylinder portion 626a is the annulus pressure plus the pressure added byspring 624.Spring 624 may exert, for example, a pressure of approximately 60-80 p.s.i. -
Cylinder 646 ofFigure 10D operates in a similar fashion tocylinder 626. Drilling fluid enterscylinder portion 646b throughaperture 622, thereby exerting the annulus pressure onside 656b ofpiston 656.Spring 644 then increases the pressure onpiston 656, causing the hydraulic fluid incylinder 646a, and therefore the hydraulic fluid in the tool hydraulic system, to be greater than the annulus pressure.Spring 644 is shown in the fully compressed position inFigure 10D . - Referring now to
Figure 10G ,enlarged piston end 656a includesseal 659 for sealing the drilling mud from the system hydraulic fluid, andscraper 661 for cleaning the cylinder bore 646 aspiston 656 reciprocates.Spring 644 seats on increaseddiameter portion 653.Piston end 636a is similar topiston end 656a illustrated inFigure 10G . - Preferably,
pistons - Referring now to
Figure 10H ,accumulator assembly 600 is illustrated placed into position incollar 12, but not locked down. To engageassembly 600 withcavity 601 incollar 12,assembly 600 is disposed abovecavity 601 and locking wings 608 (Figure 10A ) are aligned withrecesses 664.Recesses 664 are L-shaped (not shown) with the bottom portions of the L extending towardendcap 604 and end 603 ofcavity 601.Assembly 600 is lowered intocavity 601 with lockingwings 608 sliding down throughrecesses 664 untilassembly 600 seats at the bottom ofcavity 601 andtop surface 632 is substantially flush with the surface ofcollar 12.Assembly 600 is then moved towardcavity end 603 such that lockingwings 608 move into the extending bottom portions ofrecesses 664 and pressure plug 638 (Figure 10A ) pressure fits into an aperture (not shown) disposed atend 603 ofcavity 601. This forward movement also causes agap 678 to be formed betweencavity end 605 andassembly end 622. - To lock
assembly 600 into place, awedge 670 is placed intogap 678. The angled end 622 (illustrated inFigure 10C ) matingly receives theangled side 676 ofwedge 670. The wedging action of these mating surfaces ensures thatassembly 600 is moved fully forward incavity 601.Bolts 674 andnuts 672 lock downwedge 670. Further, L-shapedlocking pieces 668 are placed intorecesses 664 andbolts 666 are used to lock downwings 608. The final locked position ofassembly 600 is illustrated inFigure 10I .Fluid ports annulus 15. Fluid enteringcylinder portions apertures - Removing
accumulator assembly 600 requires a process done in reverse of the process just described. While removingassembly 600,check valves Assembly 600 may then be cleaned and/or replaced. Checkvalves assembly 600 is locked into position. Hydraulic fluid may then be added to make up for any fluid loss, and preferable fluid is added to the extent thatpistons Figure 10D . - The uplink and downlink commands used by
tool 10 are not limited to mud pulse telemetry. By way of example and not by way of limitation, other telemetry systems may include manual methods, including pump cycles, flow/pressure bands, pipe rotation, or combinations thereof. Other possibilities include electromagnetic (EM), acoustic, and wireline telemetry methods. An advantage to using alternative telemetry methods lies in the fact that mud pulse telemetry (both uplink and downlink) requires pump-on operation but other telemetry systems do not. - The down hole receiver for downlink commands or data from the surface may reside within the formation test tool or within an
MWD tool 13 with which it communicates. Likewise, the down hole transmitter for uplink commands or data from down hole may reside within theformation test tool 10 or within anMWD tool 13 with which it communicates. In the preferred embodiment specifically described, the receivers and transmitters are each positioned inMWD tool 13 and the receiver signals are processed, analyzed and sent to amaster controller 401 in theMWD tool 13 before being relayed tolocal controller 402 information testing tool 10. - The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. While the preferred embodiment of the invention and its method of use have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described herein are exemplary only, and are not limiting. Many variations and modifications of the invention and apparatus and methods disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims.
- In addition to the embodiments described previously and claimed in the appended claims, the following is a list of additional embodiments, which may serve as the basis for additional claims in this application or subsequent divisional applications.
- Embodiment 1: A downhole apparatus comprising: a drill collar having an outer surface for interaction with an earth formation; an extendable sample device recessed beneath said outer surface in a first position to extend beyond said outer surface to a second position; a sampling member coupled to said extendable sample device, said sampling member having a bore and a sampling end to extend to a position beyond said extendable sample device second position, said bore to receive at least formation fluid from the earth formation.
- Embodiment 2: The apparatus of
embodiment 1 further comprising a screen having a bore coupled to said sampling end. - Embodiment 3: The apparatus of
embodiment 2 further comprising: a scraper reciprocally disposed within said sampling member bore to frictionally engage said screen. - Embodiment 4: The apparatus of
embodiment 1 further comprising a seal pad having an aperture, said seal pad coupled to said extendable sample device, said seal pad to prevent borehole contaminants from entering said sampling member. - Embodiment 5: The apparatus of
embodiment 4 wherein said seal pad is made from a flexible material and further comprises an internal cavity to receive an adjustable volume of fluid, said adjustable volume of fluid comprising at least one of hydraulic fluid, saline solution and silicone gel. - Embodiment 6: The apparatus of
embodiment 5 wherein said volume of fluid comprises an electro-rheological fluid to receive an electrical current. - Embodiment 7: The apparatus of
embodiment 2 wherein said screen comprises at least one of a plurality of slots and a gravel pack. - Embodiment 8: The apparatus of
embodiment 7 wherein a size of said slots and a diameter of said gravel pack particles are adjustable. - Embodiment 9: The apparatus of
embodiment 1 further comprising at least one draw-down cylinder coupled to the extendable sample device to receive at least formation fluid from the earth formation. - Embodiment 10: The apparatus of
embodiment 1 further comprising an equalizer valve coupled to the extendable sample device to receive at least formation fluid from the earth formation. - Embodiment 11: The extendable sample device of
embodiment 1 comprising at least one sleeve having an aperture, each aperture of the at least one sleeve to slidably retain a piston. - Embodiment 12: A downhole apparatus comprising: a sleeve having a bore; a first piston having a bore, said first piston being slidingly retained within said sleeve bore between a retracted position and an extended position; a second piston having a bore, said second piston being slidingly retained within said first piston bore between a retracted position and an extended position; and a snorkel having a bore, said snorkel being slidingly retained within said second piston bore between a retracted position and an extended position, wherein a portion of said snorkel extends beyond said second piston bore when said snorkel is in said snorkel extended position.
- Embodiment 13: The apparatus of
embodiment 12 wherein said snorkel further comprises a screen having a bore, the apparatus further comprising: a scraper reciprocally disposed within said snorkel bore to frictionally engage said screen; a seal pad having an aperture, said seal pad coupled to said second piston, said seal pad to prevent borehole contaminants from entering said snorkel; at least one draw-down cylinder communicating with said snorkel to receive at least formation fluid from an earth formation; and an equalizer valve communicating with said snorkel to receive at least formation fluid from an earth formation. - Embodiment 14: The apparatus of
embodiment 1 further comprising: a drillstring for drilling a borehole in the earth formation; a drill bit coupled to a distal end of the drill string; and wherein the drill collar is coupled to the drill string near the drill bit, the drill collar further comprising a plurality of sensors. - Embodiment 15: The method of
embodiment 14 wherein the drill collar further comprises a stabilizer, and wherein the extendable sample device is mounted in the stabilizer. - Embodiment 16: A method of sampling a formation comprising: extending from within a drill collar a first piston radially outward; extending a snorkel from within the first piston, the snorkel to contact a borehole wall in an earth formation; removing contaminants from the snorkel; sealing a volume surrounding the snorkel to prevent contaminants from re-entering the snorkel; and measuring a property of the formation.
- Embodiment 17: The method of
embodiment 16 wherein removing contaminants from the snorkel comprises slidably engaging a scraper within the snorkel to remove the contaminants. - Embodiment 18: The method of
embodiment 16 wherein sealing a volume surrounding the snorkel comprises moving a seal pad coupled to any one of the first piston and the snorkel to form a seal with the borehole wall, and wherein forming a seal with the borehole wall comprises filling a cavity in the seal pad with at least one of hydraulic fluid, saline solution, silicone gel, and an electro-rheological fluid. - Embodiment 19: The method of
embodiment 16 further comprising filtering contaminants adjacent the snorkel. - Embodiment 20: A downhole apparatus comprising: a drill collar having an outer surface for interaction with an earth formation; an extendable sample device having a bore and recessed beneath said outer surface in a first position to extend beyond said outer surface to a second position; a draw down cylinder slidably retaining a draw down piston, said draw down piston actuatable between a first position and a second position and said draw down cylinder in fluid communication with said extendable sample device; and a flow line between said extendable sample device and said draw down cylinder, said bore and said flow line to receive at least formation fluid from the earth formation.
- Embodiment 21: The apparatus of
embodiment 1 further comprising a position indicator in communication with said draw down cylinder to signal a position of said draw down piston. - Embodiment 22: The apparatus of
embodiment 20 further comprising a second draw down cylinder slidably retaining a second draw down piston, said second draw down cylinder in fluid series with said first draw down cylinder and said extendable sample device. - Embodiment 23: The apparatus of
embodiment 20 further comprising a controller programmed to command said draw down piston to stop at a third position within said draw down cylinder between said first and second positions, and to command said draw down piston to be restarted. - Embodiment 24: The apparatus of
embodiment 20 further comprising a filter disposed in said flow line. - Embodiment 25: The apparatus of
embodiment 20 further comprising: a hydraulic circuit in fluid communication with said extendable sample device and said draw down cylinder; and said hydraulic circuit including an accumulator to communicate fluid with at least one of said extendable sample device and said draw down cylinder. - Embodiment 26: The apparatus of embodiment 25 wherein said hydraulic circuit comprises valves to divert fluid from a retract side of said extendable sample device toward an extend side of said extendable sample device said as said extendable sample device is actuated from said first position to said second position.
- Embodiment 27: A downhole apparatus comprising: a drill string including a drill bit at a distal end of the drill string and a drill collar having an outer surface for interaction with an earth formation, said drill collar disposed near said drill bit; an annulus surrounding said drill string, said annulus having a fluid pressure; an extendable sample device having a sampling member to extend beyond said outer surface; a hydraulic circuit having a fluid pressure; and a hydraulic reservoir accumulator, said hydraulic reservoir accumulator in fluid communication with said annulus and said hydraulic circuit such that said reservoir accumulator communicates said annulus fluid pressure to said hydraulic circuit.
- Embodiment 28: A method of operating a downhole apparatus comprising: disposing a drill collar in a borehole, the drill collar comprising an extendable sample device, a hydraulic circuit and a draw down piston assembly; extending a sampling member from the extendable sample device; moving a piston of the draw down piston assembly; drawing a fluid into the extendable sample device and a flow line connecting the extendable sample device and the draw down piston assembly; and accumulating a fluid pressure in the hydraulic circuit.
- Embodiment 29: The method of embodiment 28 further comprising providing the accumulated fluid pressure to at least one of extendable sample device and the draw down piston assembly.
- Embodiment 30: The method of embodiment 28 further comprising: diverting a hydraulic fluid from a retract side of the sampling member; directing the fluid to the extend side of the sampling member; and providing an additional extending force to the extend side of the sampling member.
- Embodiment 31: The method of embodiment 28 further comprising indicating a position of the draw down piston at any point during the draw down piston movement.
- Embodiment 32: The method of embodiment 31 further comprising calculating a rate of draw down piston movement and correcting another downhole measurement.
- Embodiment 33: The method of embodiment 28 wherein the draw down piston may be moved between a first and second position, further comprising: stopping the draw down piston at a third position; and re-starting movement of the draw down piston.
- Embodiment 34: The method of embodiment 28 further comprising: disposing an equalizer valve in the drill collar, the equalizer valve in fluid communication with the flow line; opening the equalizer valve; pumping the fluid in the flow line out through the equalizer valve; and cleaning the flow line.
Claims (15)
- A downhole apparatus comprising:a drill collar having an outer surface for interaction with an earth formation;an extendable sample device having a bore and recessed beneath said outer surface in a first position to extend beyond said outer surface to a second position;a draw down cylinder slidably retaining a draw down piston, said draw down piston actuatable between a first position and a second position and said draw down cylinder in fluid communication with said extendable sample device; anda flow line between said extendable sample device and said draw down cylinder, said bore and said flow line to receive at least formation fluid from the earth formation.
- The apparatus of claim 1 further comprising a second draw down cylinder slidably retaining a second draw down piston, said second draw down cylinder in fluid series with said first draw down cylinder and said extendable sample device.
- The apparatus of claim 1 further comprising a controller programmed to command said draw down piston to stop at a third position within said draw down cylinder between said first and second positions, and to command said draw down piston to be restarted.
- The apparatus of claim 1 further comprising a filter disposed in said flow line.
- The apparatus of claim 1 further comprising:a hydraulic circuit in fluid communication with said extendable sample device and said draw down cylinder; and said hydraulic circuit including an accumulator to communicate fluid with at least one of said extendable sample device and said draw down cylinder.
- The apparatus of claim 5 wherein said hydraulic circuit comprises valves to divert fluid from a retract side of said extendable sample device toward an extend side of said extendable sample device said as said extendable sample device is actuated from said first position to said second position.
- The apparatus of claim 1 further comprising:a position indicator in communication with said draw down chamber to signal a position of said draw down piston.
- The downhole apparatus of claim 1, further comprising:a drill string, including:a drill bit at a distal end of the drill string; andsaid drill collar, said drill collar disposed near said drill bit;an annulus surrounding said drill string, said annulus having a fluid pressure;a hydraulic circuit having a fluid pressure; anda hydraulic reservoir accumulator, said hydraulic reservoir accumulator in fluid communication with said annulus and said hydraulic circuit such that said reservoir accumulator communicates said annulus fluid pressure to said hydraulic circuit.
- A method of operating a downhole apparatus comprising:disposing a drill collar in a borehole, the drill collar comprising an extendable sample device, a hydraulic circuit and a draw down piston assembly;extending a sampling member from the extendable sample device beyond the drill collar;moving a piston of the draw down piston assembly;drawing a fluid into the extendable sample device and a flow line connecting the extendable sample device and the draw down piston assembly;accumulating a fluid pressure in the hydraulic circuit;diverting a hydraulic fluid from a retract side of the sampling member;directing the fluid to the extend side of the sampling member; andproviding an additional extending force to the extend side of the sampling member.
- The method of claim 9 further comprising providing the accumulated fluid pressure to at least one of extendable sample device and the draw down piston assembly.
- The method of claim 9 further comprising indicating a position of the draw down piston at any point during the draw down piston movement.
- The method of claim 11 further comprising calculating a rate of draw down piston movement and correcting another downhole measurement.
- The method of claim 9 wherein the draw down piston may be moved between a first and second position, further comprising:stopping the draw down piston at a third position; andre-starting movement of the draw down piston.
- The method of claim 9 further comprising:disposing an equalizer valve in the drill collar, the equalizer valve in fluid communication with the flow line;opening the equalizer valve;pumping the fluid in the flow line out through the equalizer valve; andcleaning the flow line.
- The method of claim 9 further comprising indicating a position of the draw down piston at any point during the draw down piston movement.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP18179418.1A EP3447242A1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US57329404P | 2004-05-21 | 2004-05-21 | |
US57329304P | 2004-05-21 | 2004-05-21 | |
US11/133,712 US7260985B2 (en) | 2004-05-21 | 2005-05-20 | Formation tester tool assembly and methods of use |
US11/133,643 US7603897B2 (en) | 2004-05-21 | 2005-05-20 | Downhole probe assembly |
PCT/US2005/018123 WO2005114134A2 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP05753972.8A EP1747347B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP05753972.8A Division EP1747347B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP05753972.8A Division-Into EP1747347B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
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EP18179418.1A Division-Into EP3447242A1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP18179418.1A Division EP3447242A1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
Publications (3)
Publication Number | Publication Date |
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EP2749733A2 true EP2749733A2 (en) | 2014-07-02 |
EP2749733A3 EP2749733A3 (en) | 2016-11-02 |
EP2749733B1 EP2749733B1 (en) | 2019-04-17 |
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Family Applications (4)
Application Number | Title | Priority Date | Filing Date |
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EP14161783.7A Active EP2749734B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP18179418.1A Withdrawn EP3447242A1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP05753972.8A Active EP1747347B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP14161780.3A Active EP2749733B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
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EP14161783.7A Active EP2749734B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP18179418.1A Withdrawn EP3447242A1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
EP05753972.8A Active EP1747347B1 (en) | 2004-05-21 | 2005-05-23 | Downhole probe assembly |
Country Status (6)
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EP (4) | EP2749734B1 (en) |
AU (1) | AU2005246425C1 (en) |
BR (1) | BRPI0511444B1 (en) |
CA (1) | CA2559248C (en) |
NO (2) | NO341423B1 (en) |
WO (1) | WO2005114134A2 (en) |
Families Citing this family (15)
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US7654321B2 (en) * | 2006-12-27 | 2010-02-02 | Schlumberger Technology Corporation | Formation fluid sampling apparatus and methods |
NZ595611A (en) * | 2009-04-23 | 2013-03-28 | H J Baker & Bro Inc | Granular feed supplement ccomprising l-lysine sulfate, vegetable oil etc. |
EP2867467B1 (en) * | 2012-07-02 | 2019-03-20 | Halliburton Energy Services, Inc. | Controlling formation tester probe extension force |
CN102900431B (en) * | 2012-09-06 | 2015-11-25 | 中国石油化工股份有限公司 | Horizontal well shutoff analogue experiment installation |
US9347295B2 (en) | 2012-11-14 | 2016-05-24 | Schlumberger Technology Corporation | Filtration system and method for a packer |
US10316657B2 (en) * | 2015-02-13 | 2019-06-11 | Baker Hughes, A Ge Company, Llc | Extendable probe and formation testing tool and method |
CN108691535B (en) * | 2017-04-06 | 2021-11-23 | 中国石油化工股份有限公司 | Formation pressure measuring instrument while drilling |
CN111997593B (en) * | 2020-09-08 | 2023-07-07 | 中国石油天然气集团有限公司 | Hydraulic control device of formation pressure measurement while drilling device |
CN112012735B (en) * | 2020-09-08 | 2023-07-07 | 中国石油天然气集团有限公司 | Stratum pressure measurement sampling chamber while drilling |
CN112709564B (en) * | 2020-11-28 | 2023-04-11 | 湖南科技大学 | Surrounding rock drilling peeping device with function of removing dirt through lens in hole and using method of surrounding rock drilling peeping device |
CN113484216B (en) * | 2021-07-06 | 2023-10-20 | 西南石油大学 | Method for evaluating water phase flowback rate and reasonable flowback pressure difference of tight sandstone gas reservoir |
CN115290383B (en) * | 2022-10-09 | 2022-12-23 | 蓝天众成环保工程有限公司 | Environmental protection engineering is with detecting soil sampling device |
CN116658154B (en) * | 2023-08-01 | 2023-09-22 | 河北赛维石油设备有限公司 | Driving nipple for wireless inclinometer while drilling |
CN118010425B (en) * | 2024-04-08 | 2024-06-04 | 山东省地矿工程勘察院(山东省地质矿产勘查开发局八〇一水文地质工程地质大队) | Groundwater fixed point sampling device for water source protection |
CN118408788B (en) * | 2024-07-02 | 2024-08-20 | 无棣建安建设工程检测有限公司 | Building engineering pile foundation quality detection sampling device |
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US3934468A (en) * | 1975-01-22 | 1976-01-27 | Schlumberger Technology Corporation | Formation-testing apparatus |
US4951749A (en) * | 1989-05-23 | 1990-08-28 | Schlumberger Technology Corporation | Earth formation sampling and testing method and apparatus with improved filter means |
US6301959B1 (en) * | 1999-01-26 | 2001-10-16 | Halliburton Energy Services, Inc. | Focused formation fluid sampling probe |
EP1301688A1 (en) * | 2000-07-20 | 2003-04-16 | Baker Hughes Incorporated | Method for fast and extensive formation evaluation |
AU2003231797C1 (en) * | 2002-05-17 | 2010-02-18 | Halliburton Energy Services, Inc. | MWD formation tester |
AU2003233565B2 (en) * | 2002-05-17 | 2007-11-15 | Halliburton Energy Services, Inc. | Method and apparatus for MWD formation testing |
US6964301B2 (en) * | 2002-06-28 | 2005-11-15 | Schlumberger Technology Corporation | Method and apparatus for subsurface fluid sampling |
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2005
- 2005-05-23 BR BRPI0511444A patent/BRPI0511444B1/en not_active IP Right Cessation
- 2005-05-23 WO PCT/US2005/018123 patent/WO2005114134A2/en not_active Application Discontinuation
- 2005-05-23 EP EP14161783.7A patent/EP2749734B1/en active Active
- 2005-05-23 EP EP18179418.1A patent/EP3447242A1/en not_active Withdrawn
- 2005-05-23 AU AU2005246425A patent/AU2005246425C1/en not_active Ceased
- 2005-05-23 EP EP05753972.8A patent/EP1747347B1/en active Active
- 2005-05-23 CA CA002559248A patent/CA2559248C/en not_active Expired - Fee Related
- 2005-05-23 EP EP14161780.3A patent/EP2749733B1/en active Active
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2017
- 2017-05-15 NO NO20170795A patent/NO341423B1/en not_active IP Right Cessation
- 2017-05-15 NO NO20170794A patent/NO341425B1/en not_active IP Right Cessation
Patent Citations (1)
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US6964905B2 (en) | 2001-07-11 | 2005-11-15 | Renesas Technology Corp. | Semiconductor device and method of manufacturing therefor |
Also Published As
Publication number | Publication date |
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NO341423B1 (en) | 2017-11-13 |
EP2749733B1 (en) | 2019-04-17 |
EP1747347A4 (en) | 2012-05-30 |
EP2749734A3 (en) | 2016-11-02 |
AU2005246425A1 (en) | 2005-12-01 |
EP2749734A2 (en) | 2014-07-02 |
CA2559248C (en) | 2009-04-28 |
AU2005246425B2 (en) | 2010-08-12 |
EP1747347A2 (en) | 2007-01-31 |
NO341425B1 (en) | 2017-11-13 |
EP2749734B1 (en) | 2019-04-17 |
EP3447242A1 (en) | 2019-02-27 |
WO2005114134A2 (en) | 2005-12-01 |
EP1747347B1 (en) | 2014-10-15 |
EP2749733A3 (en) | 2016-11-02 |
BRPI0511444A (en) | 2007-12-26 |
NO20170795A1 (en) | 2017-05-15 |
WO2005114134A3 (en) | 2005-12-22 |
BRPI0511444B1 (en) | 2017-02-07 |
CA2559248A1 (en) | 2005-12-01 |
AU2005246425C1 (en) | 2010-12-23 |
NO20170794A1 (en) | 2007-02-19 |
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