US20140327552A1 - Surface Communication System for Communication with Downhole Wireless Modem Prior to Deployment - Google Patents
Surface Communication System for Communication with Downhole Wireless Modem Prior to Deployment Download PDFInfo
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- US20140327552A1 US20140327552A1 US14/360,293 US201214360293A US2014327552A1 US 20140327552 A1 US20140327552 A1 US 20140327552A1 US 201214360293 A US201214360293 A US 201214360293A US 2014327552 A1 US2014327552 A1 US 2014327552A1
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- wireless modem
- wireless
- communication system
- transceiver assembly
- tubing
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- E21B47/122—
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
- E21B47/14—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling using acoustic waves
- E21B47/16—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling using acoustic waves through the drill string or casing, e.g. by torsional acoustic waves
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
- E21B47/13—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency
Abstract
An apparatus is made of a surface communication system for communicating wirelessly with a first wireless modem (25Mi−2) mounted within a section of tubing (14), and configured to communicate wirelessly with a second wireless modem (25Mi−1) through a tubing including the section of tubing and within a well at a distance in excess of 500 feet, comprising: a transceiver assembly (32) adapted to be positioned on the section of tubing and in close proximity with the first wireless modem (25Mi−2); transmitter electronics (36) configured to provide low power signals to the transceiver assembly to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and receiver electronics (38) configured to receive and interpret high power signals from the transceiver assembly.
Description
- The invention relates generally to a wireless communication system for communication with a wireless modem configured for use in a wellbore prior to deployment. More particularly, but not by way of limitation, the present invention relates to a wireless communication system for communication with a wireless modem configured for use in a wellbore after the wireless modem has been mounted within a housing but prior to deployment in the wellbore. The communication can be, but is not limited to testing and/or controlling the state of the wireless modem and/or a downhole tool in communication with the wireless modem.
- After a wellbore has been drilled, it is desired to perform tests of formations surrounding the wellbore. Logging tests may be performed, and samples of formation fluids may be collected for chemical and physical analyses. The information collected from logging tests and analyses of properties of sampled fluids may be used to plan and develop wellbores and for determining their viability and potential performance.
- Many types of downhole tools are used in the testing and production of hydrocarbon wells. Exemplary downhole tools include flow control valves, packers, pressure gauges, and fluid samplers. For example, fluid sampling is often conducted during drill stem testing of hydrocarbon wells. During a well test, many types of downhole tools such as flow control valves, packers, pressure gauges, and fluid samplers are lowered into the well on a pipe string. Once the packer has been set and a cushion fluid having an appropriate density is displaced in the well above the flow control or tester valve, the valve is opened and hydrocarbons are allowed to flow to the surface where the fluids are separated and disposed of during the test. At various times during the test, the downhole tester valve is closed and the downhole pressure is allowed to build up to its original reservoir pressure. During this time, downhole gauges record the transient pressure signal. This transient pressure data is analyzed after the well test in order to determine key reservoir parameters of importance such as permeability and skin damage. Also during the course of the well test, downhole fluid samples are often captured and brought to surface after the test is completed. These samples are usually analyzed in a laboratory to determine various fluid properties which are then used to assist with the interpretation of the aforementioned pressure data, establish flow assurance during commercial production phases, and determine refining process requirements among other things.
- It is often important that these fluid samples be maintained near or above the downhole pressure that existed at the time they were captured. Otherwise, as the sample is brought to surface, its pressure would naturally decrease in proportion to the natural hydrostatic gradient of the well. During this reduction in pressure, entrained gas may be released from solution, or irreversible changes such as the precipitation of asphaltenes may occur which will render the captured sample non-representative of downhole conditions. For this reason, downhole samplers often have a means to hold the captured fluid sample at an elevated pressure as it is brought to surface.
- One such means of holding captured fluid samples at an elevated pressure as they are brought to the surface is described in U.S. Patent Application Pub. No. 2008/0148838. Such a tool uses a common pressure source to maintain each sample chamber at a constant pressure preventing phase change degradation of the fluid samples even though it does not maintain the downhole temperature of the samples.
- These sampler assemblies used during well tests are typically deployed in multiple numbers together in a carrier which can position up to 8 or 9 sampler assemblies around the flow path at the same vertical position as described in U.S. Pat. No. 6,439,306. The carrier is commonly known as a SCAR (Sampler carrier) assembly and serves as a differential pressure housing. The SCAR assembly typically includes a top sub, a bottom sub, and a housing which couples the top and bottom subs together. The sampler assemblies, including their trigger mechanisms, may be attached to the top sub and enclosed within the SCAR assembly. If it is desired to capture more than one sample at the same time, the SCAR assembly design exposes each sampler to identical surrounding fluid conditions at the time of triggering. Otherwise, if the different samplers were to be distributed a vertical distance along the wellbore, then there can be no assurance that differences in pressure or temperature at the different vertical locations in the wellbore will not affect the well fluid differently causing differences in the captured fluid samples.
- Sampler assemblies of this type have traditionally been triggered using either timer mechanisms programmed at surface before the test or by rupture disks which are burst to capture a sample by the application of annulus pressure from a pressure source at the surface. An example of one timer system can be seen in U.S. Pat. No. 5,103,906, which also employs a rupture disk. An example of the rupture disk design can be found in U.S. Pat. Nos. 6,439,306, 6,450,263, and 7,562,713. The rupture disks when burst, may allow annulus fluid to enter a chamber which contains a piston. The opposing side of the piston is traditionally exposed to an atmospheric chamber. The pressure differential between annulus pressure and the atmospheric chamber generates a force on the piston which is attached to a pull rod which then moves with the piston to open a regulating valve which begins the fluid sampling process as described in U.S. Pat. No. 6,439,306.
- When the samplers are triggered using rupture disks and a pressure source from the surface in this fashion and it is desired to take samples at different times, many different trigger mechanisms with multiple rupture disks having different burst pressures are needed. Because each disk has an accuracy range associated with it, and it is further desirable to have an unused safety range of pressure between each disk to avoid inadvertently bursting the wrong disk, and because other tools in the test string also rely on this same method for actuation, it is often the case that the maximum allowable casing pressure limits the number of disks that can be deployed in the test string. To overcome this limitation, samplers have traditionally been triggered all at once or in a limited number of combined groups. This restriction limits the flexibility of being able to take many samples at different times during a well test.
- Wireless modems for downhole use exist. Exemplary wireless modems use various communication mediums such as acoustic waves, electromagnetic waves or pressure pulse. Acoustic modems suitable for downhole use are provided with an acoustic transceiver for wireless communication while the acoustic modem is downhole,
- Such a wireless modem can be used to form a wireless triggering system for a downhole fluid sampler. The wireless trigger can be fitted to multiple samplers permitting complete flexibility in choosing when, and in what combination, to fire the downhole samplers, and thus removing the aforementioned casing pressure limitations associated with conventional rupture disk-fired samplers.
- Preparing individual sampler assemblies can require substantial time. Each individual sampler assembly having an acoustic modem and associated trigger must be programmed and the sampler tested for leaks. The sampler assemblies must also be sealed within the SCAR assembly prior to downhole deployment. Once the samplers have been assembled in the SCAR assembly, there is no longer physical access to the individual samplers. Therefore, further testing and reconfiguration of the sampling assembly is limited because a sampling assembly must be uninstalled in order to be tested or reconfigured. It would be advantageous to be able to communicate with the individual samplers having acoustic modems and associated triggers while the assembled SCAR assembly is at the surface without disassembling it.
- An acoustic modem forming part of a sampler trigger will typically have a port for forming a wired communication link with a computer while the acoustic modem is at the surface. The wired communication link is used for testing and configuring the acoustic modem before the acoustic modem is installed within a housing which may form a section of tubing, such as a mandrel. Once the acoustic modem is installed within the housing, the port is enclosed and unavailable unless the acoustic modem is removed from the housing.
- It would therefore be useful to have a method and device to communicate with a wireless modem configured for use in a wellbore after the wireless modem has been mounted within a housing but prior to deployment in the wellbore so that the programming of the wireless modem and/or a downhole tool connected thereto could be modified without disassembly.
- In a first aspect, an apparatus is disclosed. The apparatus is made of a surface communication system for communicating wirelessly with a first wireless modem mounted within a section of tubing, and configured to communicate wirelessly with a second wireless modem through a tubing including the section of tubing and within a well at a distance in excess of 500 feet, comprising: a transceiver assembly adapted to be positioned on the section of tubing and in close proximity with the first wireless modem; transmitter electronics configured to provide low power signals to the transceiver assembly to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and receiver electronics configured to receive and interpret high power signals from the transceiver assembly.
- In a second aspect, a method is disclosed. The method comprises the steps of: programming a surface communication system with at least one instruction to be transmitted to a first wireless modem, the first wireless modem configured to communicate wirelessly with a second wireless modem within a well at a distance in excess of 500 feet; placing a transceiver assembly of the surface communication system in close proximity to the first wireless modem prior to deployment of the first wireless modem in the well; and transmitting a low power wireless signal from the transceiver assembly to the first wireless modem including the at least one instruction.
- Certain embodiments of the present invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
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FIG. 1 shows a schematic view of an acoustic telemetry system according to an embodiment of the present invention; -
FIG. 2 shows a schematic of an acoustic modem as used in accordance with the present disclosure; -
FIG. 3 is a longitudinal sectional view of a sampling apparatus in accordance with an embodiment described herein; -
FIG. 4A is a cross-sectional view of the sampling apparatus taken along thelines 4A-4A depicted inFIG. 3 ; -
FIG. 4B is a cross-sectional view of the sampling apparatus taken along thelines 4B-4B depicted inFIG. 3 ; -
FIG. 5 is a diagrammatic view of a wireless communication system according to an embodiment of the present disclosure; -
FIG. 6 is a block diagram of a wireless transceiver of the wireless communication system depicted inFIG. 5 ; and -
FIG. 7 is a diagrammatic view of another version of a wireless communication system described within the present disclosure. - A surface communication system described herein with reference to
FIGS. 5 , 6 and 7 is configured to wirelessly communicate with a wireless modem prior to deployment of the modem within a wellbore. This is particularly applicable to downhole tools and communication systems which are used in testing installations such as are used in oil and gas wells or the like. -
FIG. 1 shows a schematic view of a testing installation. In particular, once a well 10 has been drilled through a formation, the drill string can be used to perform tests, and determine various properties of the formation through which thewell 10 has been drilled. In the example ofFIG. 1 , the well 10 has been lined with a steel casing 12 (cased hole) in the conventional manner, although similar systems can be used in unlined (open hole) environments. In order to test the formations, it is preferable to place asampling apparatus 13 in the well close to regions to be tested, to be able to isolate sections or intervals of the well, and to convey fluids from the regions of interest to the surface. This is commonly done using a jointed tubular drill pipe, drill string, production tubing, or the like (collectively, tubing 14) which extends from well-head equipment 16 at the surface (or sea bed in subsea environments) down inside the well 10 to a zone of interest. The well-head equipment 16 can include blow-out preventers and connections for fluid, power and data communication. - A
packer 18 is positioned on thetubing 14 and can be actuated to seal the borehole around thetubing 14 at the region of interest. Various pieces ofdownhole equipment 20 are connected to thetubing 14 above or below thepacker 18. Thedownhole equipment 20 may also be referred to herein as a “downhole tool”. In any event, thedownhole equipment 20 may include, but is not limited to: additional packers; tester valves; circulation valves; downhole chokes; firing heads; TCP (tubing conveyed perforator) gun drop subs; samplers; pressure gauges; downhole flow meters; downhole fluid analyzers; and the like. - The surface communication system will be discussed in detail below by way of example with the
sampling apparatus 13 being a particular type ofdownhole equipment 20. - In the embodiment of
FIG. 1 , atester valve 24 is located above thepacker 18, and thesampling apparatus 13 is located below thepacker 18, although thesampling apparatus 13 could also be placed above thepacker 18 if desired. Thetester valve 24 is connected to a wirelessmodem 25Mi+ 1. Agauge carrier 28 a may also be placed adjacent totester valve 24, with each pressure gauge also being associated with an acoustic modem. As will be discussed in more detail below with reference toFIGS. 2 and 3 , thesampling apparatus 13 includes a plurality of the wireless modems 25Mi+(2-9). The wireless modems 25Mi+(1-9), operate to allow electrical signals from thetester valve 24, thegauge carrier 28 a, and thesampling apparatus 13 to be converted into acoustic signals for transmission to the surface via thetubing 14, and to convert acoustic tool control signals from the surface into electrical signals for operating thetester valve 24 and thesampling apparatus 13. The term “data,” as used herein, is meant to encompass control signals, tool status, and any variation thereof whether transmitted via digital or analog. -
FIG. 2 shows a schematic of the wireless modem 25Mi+2 in more detail. The modem 25Mi+2 comprises ahousing 30 supporting atransceiver assembly 32 which can be a piezo electric actuator or stack, and/or a magnetorestrictive element which can be driven to create an acoustic signal in thetubing 14. The modem 25Mi+2 can also include an accelerometer 34 and/or monitoring piezo sensor 35 for receiving acoustic signals. Where the modem 25Mi+2 is only required to receive acoustic messages, thetransceiver assembly 32 may be omitted. The wireless modem 25Mi+2 also includestransmitter electronics 36 andreceiver electronics 38 located in thehousing 30 and power is provided by apower source 40, such as one or more lithium batteries. Other types of power supply may also be used. For configuration and testing at the surface, the wireless modem 25Mi+2 includes aport 41 connected to thetransmitter electronics 36 and thereceiver electronics 38 for forming a wired communication link with a computer (not shown). - The
transmitter electronics 36 are arranged to initially receive an electrical output signal from asensor 42, for example from thedownhole equipment 20 provided from an electrical or electro/mechanical interface. Thesensor 42 can be a pressure sensor to monitor a nitrogen charge as discussed below, or a position sensor to track a displacement of a piston which controls a sample fluid displacement in a sampler assembly discussed below. Thesensor 42 may not be located in thehousing 30 as indicated inFIG. 2 . For example, thesensor 42 can be located in the sampler assembly. For example, the sensor may connect to the sampler trigger PCB which would in turn connect to the modem as discussed below. Such signals are typically digital signals which can be provided to amicro-controller 43 which modulates the signal in any number of known ways such as PSK, QPSK, QAM, and the like. The micro-controller 43 can be implemented as a single micro-controller or two or more micro-controllers working together. In any event, the resulting modulated signal is amplified by either a linear ornon-linear amplifier 44 and transmitted to thetransceiver assembly 32 so as to generate an acoustic signal (which is also referred to herein as an acoustic message) in the material of thetubing 14. - The acoustic signal passes along the
tubing 14 as a longitudinal and/or flexural wave and comprises a carrier signal with an applied modulation of the data received from thesensors 42. The acoustic signal typically has, but is not limited to, a frequency in the range 1-10 kHz, preferably in the range 1-5 kHz, and is configured to pass data at a rate of, but is not limited to, about 1 bps to about 200 bps, preferably from about 5 to about 100 bps, and more preferably about 50 bps. The data rate is dependent upon conditions such as the noise level, carrier frequency, and the distance between the repeaters. A preferred embodiment of the present disclosure is directed to a combination of a short hop wireless modems 25Mi−1, 25M and 25Mi+1 for transmitting data between the surface and thedownhole equipment 20, which may be located above and/or below thepacker 18. The wireless modems 25Mi−1 and 25M can be configured as repeaters of the acoustic signals. Other advantages of the present system exist. - The
receiver electronics 38 of the wireless modem 25Mi+1 are arranged to receive the acoustic signal passing along thetubing 14 produced by thetransmitter electronics 36 of thewireless modem 25M. Thereceiver electronics 38 are capable of converting the acoustic signal into an electric signal. In a preferred embodiment, the acoustic signal passing along thetubing 14 excites thetransceiver assembly 32 so as to generate an electric output signal (voltage); however, it is contemplated that the acoustic signal may excite the accelerometer 34 or theadditional transceiver assembly 32 so as to generate an electric output signal (voltage). This signal is essentially an analog signal carrying digital information. The analog signal is applied to asignal conditioner 48, which operates to filter/condition the analog signal to be digitalized by an A/D (analog-to-digital)converter 50. The A/D converter 50 provides a digitalized signal which can be applied to amicrocontroller 52. Themicrocontroller 52 is preferably adapted to demodulate the digital signal in order to recover the data provided by thesensor 42, or provided by the surface. The type of signal processing depends on the applied modulation (i.e. PSK, QPSK, QAM, and the like). - The modem 25Mi+2 can therefore operate to transmit acoustic data signals from
sensors 42 in thedownhole equipment 20 along thetubing 14. In this case, the electrical signals from thedownhole equipment 20 are applied to the transmitter electronics 36 (described above) which operate to generate the acoustic signal. The modem 25Mi+2 can also operate to receive acoustic control signals to be applied to thesampling apparatus 13. In this case, the acoustic signals are demodulated by the receiver electronics 38 (described above), which operate to generate the electric control signal that can be applied to thesampling apparatus 13. - Returning to
FIG. 1 , in order to support acoustic signal transmission along thetubing 14 between the downhole location and the surface, a series of the wireless modems 25Mi−1 and 25M, etc. may be positioned along thetubing 14. Thewireless modem 25M, for example, operates to receive an acoustic signal generated in thetubing 14 by the modem 25Mi−1 and to amplify and retransmit the signal for further propagation along thetubing 14. The number and spacing of the wireless modems 25Mi−1 and 25M will depend on the particular installation selected, for example on the distance that the signal must travel. A typical spacing between the wireless modems 25Mi−1, 25M, and 25Mi+1 is around 1,000 ft, but may be much more or much less in order to accommodate all possible testing tool configurations. When acting as a repeater, the acoustic signal is received and processed by thereceiver electronics 38 and the output signal is provided to themicrocontroller 52 of thetransmitter electronics 36 and used to drive thetransceiver assembly 32 in the manner described above. Thus an acoustic signal can be passed between the surface and the downhole location in a series of short hops. - The role of a repeater is to detect an incoming signal, to decode it, to interpret it and to subsequently rebroadcast it if required. In some implementations, the repeater does not decode the signal but merely amplifies the signal (and the noise). In this case the repeater is acting as a simple signal booster. However, this is not the preferred implementation selected for wireless telemetry systems of the present invention.
- The
wireless modems 25M, 25Mi−1, and 25Mi+1 will either listen continuously for any incoming signal or may listen from time to time. - The acoustic wireless signals, conveying commands or messages, propagate in the transmission medium (the tubing 14) in an omni-directional fashion, that is to say up and down. It is not necessary for the modem 25Mi+1 to know whether the acoustic signal is coming from the
wireless modem 25M above or one of the wireless modems 25Mi+(2-9) below. The destination of the acoustic message is preferably embedded in the acoustic message itself. Each acoustic message contains several network addresses: the address of the wireless modem 25Mi−1, 25M, 25Mi+1, or 25Mi+(2-9) originating the acoustic message and the address of the wireless modem 25Mi−1, 25M or 25Mi+1 that is the destination. Based on the addresses embedded in the acoustic messages, the wireless modem 25Mi−1, 25M, or 25Mi+1 functioning as a repeater will interpret the acoustic message and construct a new message with updated information regarding the wireless modem 25Mi−1, 25M, 25Mi+1, or 25Mi+(2-9) that originated the acoustic message and the destination addresses. Acoustic messages will be transmitted from the wireless modems 25Mi−1, 25M, and 25Mi+1 and slightly modified to include new network addresses. - Referring again to
FIG. 1 , asurface wireless modem 28 d is provided at thehead equipment 16 which provides a connection between thetubing 14 and a data cable orwireless connection 54 to acontrol system 56 that can receive data from thedownhole equipment 20 and provide control signals for its operation. - In the embodiment of
FIG. 1 , the acoustic telemetry system is used to provide communication between the surface and the downhole location. - Referring to
FIGS. 3 , 4A and 4B, thesampling apparatus 13 is preferably mounted as part of thetubing 14, and includes acarrier 60 having afirst sub 62, asecond sub 64, and ahousing section 66 coupled between thefirst sub 62 and thesecond sub 64. Aninner bore 70 is defined through thecarrier 60 and includes aninner passageway 72 of thefirst sub 62, and aninner passageway 74 of thesecond sub 64. According to one embodiment, thehousing section 66 defines theinner bore 70 inside thesampling apparatus 13 in which one or more sampler assemblies 80 may be positioned. In the illustrated embodiment, eight sampler assemblies 80 a-h (SeeFIG. 4 ) are positioned in theinner bore 70 although more or less of the sampler assemblies 80 can be provided. As will be discussed in more detail below, each of the sampler assemblies 80 has a first end 82, as depicted inFIG. 3 by 82 c and 82 g, which is connected to thefirst sub 62, and a second end 84 which is connected to acentralizer assembly 85 which is positioned just above thesecond sub 64. - It should be noted that each of the sampler assemblies 80 a-h is substantially similar in construction and function and so only one of the
sampler assemblies 80 c will be described in detail hereinafter. In general, thesampler assembly 80 c is provided with the wirelessmodem 25Mi+ 2, thepower source 40 c, anactuator 92 c, asampler device 94 c, aswivel assembly 96 c, afirst connector 98 c, and a second connector 100 c, all of which are rigidly connected together to form an integral assembly. The second connector 100 c is connected to thecentralizer assembly 85. Thecentralizer assembly 85 is positioned within thehousing section 66 to allow thesampler assembly 80 c to expand and contract with changes in temperature. - Each of the sampler devices 94 preferably forms an independent self-contained system including a nitrogen charge 102. The prior art uses a single nitrogen reservoir to supply all samplers. Hence a failure of their nitrogen storage system would result in a much larger release of energy (i.e., explosion) than the nitrogen charge 102 for each of the sampler devices 94.
- The
sampling apparatus 13 is preferably a modular tool made up of thecarrier 60 and a plurality of the sampler assemblies 80 a-h which can be independently controlled by the surface using the wireless modems 25Mi+(2-9). The wirelessmodem 25Mi+ 2, for example, communicates with the actuator 92 for supplying control signals to the actuator 92 and for returning a signal to the surface confirming a sampling operation. Incorporating the wireless modem 25Mi+(2-9) within the sampler assemblies 80 a-h, for example, permits independent actuation of individually addressed sampler devices 94, via surface activation while also configured to provide receipt of actuation and other diagnostic information. The diagnostic information can include, for example, status of thetransmitter electronics 36, status of thereceiver electronics 38, status of telemetry link, battery voltage, or an angular position of motor shaft as described hereinafter. In the embodiment shown inFIG. 3 , the actuator 92 is integrated both electrically and mechanically with the wirelessmodem 25Mi+ 2. Each sampler assembly 80 a-h is preferably fully independent providing full individual redundancy. In other words, because each sampler assembly 80 a-h has its own wireless modem 25Mi+(2-9),power source 40, actuator 92, and sampler device 94, full redundancy is achieved. For example, if for any reason one of the sampler assemblies 80 a-h were to fail, the remaining sampler assemblies 80 a-h can be fired fully independently. - With respect to the
sampler assembly 80 c, thefirst connector 98 c is positioned at thefirst end 82 c and preferably serves to solidly connect the wireless modem 25Mi+2 to thefirst sub 62 to provide a suitable acoustic coupling into thetubing 14. Thefirst connector 98 c can be implemented in a variety of manners, but for simplicity and reliability thefirst connector 98 c is preferably implemented as a threaded post which can engage with a threaded hole within thefirst sub 62. The second connector 100 c is positioned at thesecond end 84 c and preferably serves to connect thesampler device 94 c to thecentralizer assembly 85 which serves to maintain thesecond end 84 c of thesampler device 94 c out against thehousing section 66. The second connector 100 c is preferably non-rotatably connected to thecentralizer assembly 85, and for this reason thesampler assembly 80 c is provided with theswivel assembly 96 c to permit installation of thesampler assembly 80 c into thefirst sub 62. - More particularly, to install the
sampler assembly 80 c within thecarrier 60, the second connector 100 c is first attached to thecentralizer assembly 85, and then thefirst connector 98 c is positioned within the threaded hole within thefirst sub 62. Theswivel assembly 96 c permits the wirelessmodem 25Mi+ 2,power source 40 c,actuator 92 c andsampler device 94 c to be rotated to thread thefirst connector 98 c into the threaded hole of thefirst sub 62 or thesecond sub 64 while thesecond connector 100 remains fixed to the centralizer. Theswivel assembly 96 c can be located in various positions within thesampler assembly 80 c. - The
power source 40 c preferably includes one or more batteries, such as Lithium-thionyl chloride batteries with suitable circuitry for supplying power to the wirelessmodem 25Mi+ 2, as well as theactuator 92 c. Thepower source 40 c may also be provided with circuitry for de-passivating the battery before the actuator 92 c is enabled to cause thesampler device 94 c to collect a sample. Circuitry for de-passivating a battery is known in the art and will not be described in detail herein. - The
power source 40 c can be shared between the wireless modem 25Mi+2 and theactuator 92 c which provides for a shorter and lessexpensive power source 40 c. That is, assuming that the wireless modem 25Mi+2 and theactuator 92 c use a voltage level greater than ˜5 volts to operate and that a single battery cell using technology suitable for downhole applications typically produces a voltage level ˜3 volts then at least 2 battery cells are required in series to produce a voltage greater than ˜5-6 volts. If the wireless modem 25Mi+2 and theactuator 92 c retain its own battery system then each would require at least 2 cells in series to provide an adequate voltage level, which would increase the length of thepower source 40 c. - The
mechanical module 106 c is connected to thesampler device 94 c for actuating thesampler device 94 c to collect a sample. Theelectronics module 108 c functions to interpret the control signals received from the wirelessmodem 25Mi+ 2, and to provide one or more signals to cause themechanical module 106 c to actuate thesampler device 94 c. In a preferred embodiment, theelectronics module 108 c can be provided with one or more microcontrollers, and other circuitry for controlling themechanical module 106 c. Methods of making and using themechanical module 106 c and theelectronics module 108 c are known in the art and so a detailed explanation of same is not necessary to teach one skilled in the art how to make and use thesampler assembly 80 c. - Shown in
FIGS. 3 and 5 are exemplary embodiments of asurface communication system 120 constructed in accordance with the present disclosure. In general, thesurface communication system 120 is provided with atransceiver assembly 122, anelectronics package 124 and acommunication link 126 connecting thetransceiver assembly 122 to theelectronics package 124. Thetransceiver assembly 122 can be a pressure actuator for pulse telemetry, an antenna for electromagnetic telemetry, or a piezo electric actuator or stack, and/or a magnetorestrictive element which can be driven to provide an acoustic signal. Thetransceiver assembly 122 will be described herein as providing acoustic signals which form stress waves within a carrier, such as thetubing 14. Thetubing 14 may be constructed of steel in a manner known in the art. - The wireless modems 25Mi+(2-9) are mounted within a section of the
tubing 14 formed by thehousing section 66, thefirst sub 62, and thesecond sub 64. The wireless modems 25Mi+(2-9) are configured to communicate wirelessly with another (or second) wireless modem through thetubing 14 including the section oftubing 14 and within the well 10 at a distance in excess of 500 feet. In general, theelectronics package 124 and thetransceiver assembly 122 are adapted to wirelessly communicate with one or more of the wireless modems 25Mi+(2-9) while the wireless modems 25Mi+(2-9) are at the surface and prior to being deployed within thewell 10. - More particularly, the
transceiver assembly 122 is positioned in close proximity, e.g., within 20 feet, to one or more of the wireless modems 25Mi+(2-9). For example, as depicted inFIG. 3 thetransceiver assembly 122 is positioned on thehousing section 66 generally adjacent to the wireless modems 25Mi+(2-9) such that stress waves generated by thetransceiver assembly 122 are introduced into thehousing section 66. The stress waves travel to the wireless modems 25Mi+(2-9) via thehousing section 66, and thefirst sub 62. Likewise, stress waves introduced by the wireless modems 25Mi+(2-9) travel to thetransceiver assembly 122 via thefirst sub 62 and thehousing section 66. The stress waves generated by thetransceiver assembly 122 and introduced by the wireless modems 25Mi+(2-9) can be indicative of data, addresses, instructions, and/or the like such that bidirectional communication is provided between thetransceiver assembly 122 and the wireless modems 25Mi+(2-9). - The
transceiver assembly 122 converts the stress waves provided by the wireless modems 25Mi+(2-9) into electrical signals and transmits the electrical signals to theelectronics package 124 for interpretation. Likewise, thetransceiver assembly 122 receives electrical signals from theelectronics package 124 and convert such electrical signals into stress waves to be communicated to the wireless modems 25Mi+(2-9). Thus, it can be seen that thesurface communication system 120 permits the operator to communicate with one or more of the wireless modems 25Mi+(2-9) wirelessly and after thesampling apparatus 13 has been fully assembled. In particular, once thesampling apparatus 13 has been fully assembled, thehousing section 66 covers and seals theports 41 of the wireless modems 25Mi+(2-9). - As discussed above, the wireless modems 25Mi+(2-9) can be configured to communicate through the
tubing 14 at distances in excess of 500 feet. In order to communicate with the wireless modems 25Mi+(2-9) at much closer distances and without requiring reconfiguration of the wireless modems 25Mi+(2-9), the transmitter electronics 130 (FIG. 5 ) is configured to provide low power signals to thetransceiver assembly 122 to cause thetransceiver assembly 122 to generate low power wireless signals into the section oftubing 14 to be received and interpreted by the one or more of the wireless modem 25Mi+(2-9). The receiver electronics 132 (FIG. 6 ) is configured to receive and interpret high power signals from thetransceiver assembly 122. The high power signals are generated by one or more of the wireless modems 25Mi+(2-9) to propagate in excess of 500 feet within thetubing 14. Signal power diminishes as length from the wireless modems 25Mi+(2-9) increase. Thus, the high power signals received by the transceiver assembly 122 (that is in close proximity to the wireless modems 25Mi+(2-9) at the surface) are much stronger than the same signals received by another wireless modem when thesampling apparatus 13 is deployed in thewell 10. As will be explained in more detail below, the reception and interpretation of the high power signals can be implemented by thereceiver electronics 132 by using afirst amplifier 136 having a low gain or even negative gain to provide electrical signals from thetransceiver assembly 122 to afirst processing device 138. - Because the time required to prepare the individual sampler assemblies 80, charge the sampler assemblies 80 with nitrogen, and test for leaks around the
housing section 66 can be quite long, it is undesirable to disassemble thesampling apparatus 13 to provide access to thehardwired ports 41 of the wireless modems 25Mi+(2-9). Therefore, it is advantageous to be able to communicate with the individual sampler assemblies 80 while the assembledsampling apparatus 13 is at the surface without disassembling anything. For example, if there is an unforeseen delay in rig operations, it may be necessary to put the electronic systems into deep sleep mode in order to preserve battery power so as not to reduce the time that thesampling apparatus 13 can operate downhole. Thesurface communication system 120 preferably allows communication with the electronics module 108 by placing thetransceiver assembly 122 against thehousing section 66 and/or thefirst sub 62 or thesecond sub 64 and more generally allows communication with any wireless-enabled tool when the wireless-enabled tool is at the surface, even after the wireless-enabled tool has been assembled or otherwise deeply embedded within another tool. - Each wireless-enabled tool, such as the
sampling apparatus 13, will require some degree of configuration before being run downhole. For example, the wireless modems 25Mi+(2-9) can be configured so that the wireless modems 25Mi+(2-9) understand the intended function of the testing application and instructions regarding the particular sampler device 94 that the particular wireless modems 25Mi+(2-9) are connected to. The wireless modems 25Mi+(2-9) can be configured at the surface for this functionality. In particular, memory logs of the wireless modems 25Mi+(2-9) can be initialized, and any desired time delay before the sampler device 94 becomes functional can be programmed. Finally, time clocks of the wireless modems 25Mi+(2-9) and the electronics module 108 can be synchronized with a surface data acquisition/control computer. This initial configuration can be performed on the wireless modems 25Mi+(2-9) from inside a lab cabin by physically connecting the wireless modems 25Mi+(2-9) to a surface control computer with a cable. Once configured, the wireless modems 25Mi+(2-9) can then be moved outside for assembly with the sampler devices 94. The sampler devices 94 can then be charged with nitrogen, for example, and then connected to thefirst sub 62,second sub 64, and thehousing section 66. Finally, final pressure checks will be usually made—all of which represent a significant amount of preparation effort and time. - Should any unforeseen change in rig schedule occur, the
surface communication system 120 can be utilized to reprogram a time delay for the wireless modems 25Mi+(2-9) and/or the electronics module 108 or temporarily switch them off Hence, thesurface communication system 120 is advantageous since thetransceiver assembly 122 can be placed onto the outside surface of the assembledsampling apparatus 13 and acoustically transmit parameter changes and to check that thesampling apparatus 13 is functioning properly. - One particularly desirable application for the
surface communication system 120 is to manage deep-sleep modes before running tools in the well 10 in order to preserve battery autonomy. For example, thesampling apparatus 13 could be put into a deep sleep state for a predetermined period of time, during which all acoustic processing is stopped and only a low power clock function is kept running, thereby reducing battery consumption to an absolute minimum. After the designated time delay, thesampling apparatus 13 would awaken and resume acoustic processing, allowing communication via thesurface communication system 120. To provide greater flexibility in managing rig delays, thesampling apparatus 13 could “wake-up” every 15 minutes or so to an idle state at pre-programmed times to check for a communication signal from thesurface communication system 120. If no signal is present, thesampling apparatus 13 would then revert to sleep mode. Thesurface communication system 120 may also be used on a rig floor to make a final check of all wireless enabled tools before they are lowered through the rotary table. - Exemplary states of the wireless modems 25Mi+(2-9) include the sleep state and the idle state discussed above. In the sleep state, one or more electronic components or functionalities are powered off while certain electronic components or functionalities are powered on. Depending on the microcontroller and programmed logic, examples of the portion of the wireless modems 25Mi+(2-9) (i.e., electronic components and/or functionalities) that may be powered off or on may include, certain peripheral components, the RAM, and possibly the MCU clock. In the idle state, the wireless modems 25Mi+(2-9) are powered on and waited for a command.
- The
surface communication system 120 is preferably portable and suitable for Zone 0 operation. It could either be powered by battery or via a power cable. A hand-carryable enclosure, containing one or more batteries, thetransceiver assembly 122, and/or theelectronics package 124 can be used. Theelectronics package 124 can be connected via a short cable (communication link 126) to thetransceiver assembly 122, which may have a magnetic base for maintaining thetransceiver assembly 122 securely attached to thehousing section 66, for example. Theelectronics package 124 may provide simple built-in tool-check commands, or theelectronics package 124 may have the ability to support more complex programming/configuration of any acoustic-enabled downhole tools, such as thesampling apparatus 13. Theelectronics package 124 can operate autonomously or theelectronics package 124 could be connected to auser interface device 140, such as a portable computer, as shown inFIG. 5 to provide an additional communication interface and display or processing capabilities. - Shown in
FIG. 6 is a block diagram of thesurface communication system 120. Theelectronics package 124 of thesurface communication device 120 includestransmitter electronics 130 andreceiver electronics 132. Power for thetransmitter electronics 130 and thereceiver electronics 132 can be provided by means of one or more battery, such as alithium battery 134. Other types of power supply may also be used. - The
transmitter electronics 130 are arranged to initially receive an electrical output signal from theuser interface device 140 indicative of a predetermined command or instruction to be provided to one or more of the wireless modems 25Mi+(2-9). For example, the command can identify one or more of the wireless modems 25Mi+(2-9), as well as include instructions to place one or more of the wireless modems 25Mi+(2-9) into a deep sleep mode for a predetermined period of time, during which all acoustic processing is stopped and only a low power clock function is kept running to reduce battery consumption as discussed above. - Such signals are typically digital signals which can be provided to a
processing device 142, such as a logic device or a microprocessor. The logic device may not operate on a set of instructions stored on a non-transitory computer readable medium. Exemplary logic devices include a field programmable gate array or an application specific integrated circuit. The microprocessor operates on a set of instructions stored on a non-transitory computer readable medium. The microprocessor can be implemented in various forms, such as one or more microprocessor, micro-controller or the like. In either case, theprocessing device 142 modulates the signal in any number of known ways such as PSK, QPSK, QAM, and the like. Theprocessing device 142 can be implemented as a single device, or two or more devices working together. Thetransmitter electronics 130 and thereceiver electronics 132 are configured to use the same data rate, and encoding scheme(s) as the wireless modems 25Mi+(2-9) to permit communication therebetween. - The resulting modulated signal is amplified by either a linear or
non-linear amplifier 144 and transmitted to thetransceiver assembly 122 so as to generate an acoustic signal (which is also referred to herein as an acoustic message) in the material of thesampling apparatus 13. Theamplifier 144 is adapted to produce electrical signals to cause thetransceiver assembly 122 to generate low power signals for reception by the wireless modems 25Mi+(2-9). The primary reason for transmitting at low or reduced power by thesurface communication system 120 with the wireless modems 25Mi+(2-9) is to avoid saturating thetransceiver assembly 32 when thesurface communication system 120 is placed very near the downhole tool. Low power signals, as used herein, refers to signals having a power in a range between 0.1 to 3 watts, and preferably from 0.1 to 1.5 watts. - The
user interface device 140 can be one or more devices capable of receiving operator input and then providing signals to theprocessing device 142. For example, theuser interface device 140 can be a keyboard, keypad, microphone, tablet and/or the like. Alternatively, theuser interface device 140 can be a separate portable computer as set forth inFIG. 5 . - The
surface communication system 120 can therefore operate to transmit acoustic data signals from a user, either preprogrammed or from a user input device, such as a portable computer, to the wireless modems 25Mi+(2-9) prior to deployment. In this case, electrical signals from the user are applied to the transmitter electronics 130 (described above) which operate to generate the acoustic signal. Thesurface communication system 120 can also operate to receive acoustic response signals from the wireless modems 25Mi+(2-9). In this case, the acoustic signals are demodulated by the receiver electronics 132 (described above), which operate to generate the electrical response signal giving information about the state of particular ones of the wireless modems 25Mi+(2-9). - Further, it should be understood that the modems and the transceiver assembly have been described herein by way of example as acoustic modems using stress waves as a communication medium. It should be understood that the modems and the
transceiver assembly 122 can use other types of wireless mediums, such as pressure pulse signals, electromagnetic signals, mechanical signals and the like. As such, any type of telemetry may be used to pass signals between the transceiver assembly and the modems. - Shown in
FIG. 7 is another example of asurface communication system 120 a constructed in accordance with the present disclosure. Thesurface communication system 120 a operates in a similar manner as thesurface communication system 120 discussed above, but is implemented utilizing a commercially available portable device, such as a cellular telephone sold under thetrademark IPHONE version 4 and produced by the Apple Corporation. Thewireless communication system 120 a can be provided with aspeaker 150, amicrophone 152, adisplay 154, one ormore communication devices 156, andinput unit 158, a non-transitory computer readable medium such as amemory 159 and aprocessor 160. Thespeaker 150, themicrophone 152, thedisplay 154, the one ormore communication devices 156, theinput unit 158 and the memory 159 (collectively devices) are adapted to communicate either directly or indirectly with theprocessor 160 such that theprocessor 160 can either provide data and/or read data read data from such devices. Thesurface communication system 120 a may also be provided with avolume control 162 for a purpose to be described hereinafter. Thevolume control 162 can either be a physical switch, or such functionality can be programmed into or provided by theprocessor 160. - The
speaker 150 and amicrophone 152 form parts of atransceiver assembly 164 for communicating with the wireless modems 25Mi+(2-9) by thehousing section 66,first sub 62 andsecond sub 64. In particular, themicrophone 152 can be used to receive and forward acoustic signals to theprocessor 160, and thespeaker 150 can be driven by theprocessor 160 to produce acoustic signals. Thevolume control 162 controls the level of the acoustic signals that are generated by thespeaker 150. Theprocessor 160 can be constructed in a similar manner as theprocessing device 142, discussed above. - The
display 154 can be a liquid crystal display or any other display suitable for use in a portable device. The one ormore communication devices 156 can be a cellular telephone, and/or a short range communication system such as that sold under the trademark Bluetooth. Communication devices such as cellular telephones and/or the like are well known to those skilled in the art and so a detailed description of how to make and use same is not deemed necessary herein. Theinput unit 158 can be a keyboard and/or a touchscreen and serves to provide user input to theprocessor 160. Thememory 159 can be random access memory, flash memory or the like. - In use, the
microphone 152 can be used to record acoustic signals indicative of predetermined instructions and save such acoustic signals in a file on thesurface communication system 120 a. Once the acoustic signals have been recorded and saved, files can be selected utilizing theinput unit 158 and played by thespeaker 150 to communicate such acoustic signals to the wireless modems 25Mi+(2-9). For example, one of the files can be selected and then actuated for playing by thespeaker 150. Thesurface communication system 120 a can then be placed on to thehousing section 66 of thesampling apparatus 13 such that thehousing section 66 receives the acoustic signals generated by thespeaker 150 and conveys such acoustic signals via stress waves to the wireless modems 25Mi+(2-9). - Although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of the present invention. Accordingly, such modifications are intended to be included within the scope of the present invention as defined in the claims.
Claims (15)
1. A surface communication system for communicating wirelessly with a first wireless modem mounted within a section of tubing, and configured to communicate wirelessly with a second wireless modem through a tubing including the section of tubing and within a well at a distance in excess of 500 feet, comprising:
a transceiver assembly adapted to be positioned on the section of tubing and in close proximity with the first wireless modem;
transmitter electronics configured to provide low power signals to the transceiver assembly to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and
receiver electronics configured to receive and interpret high power signals from the transceiver assembly.
2. The surface communication system of claim 1 , wherein the transceiver assembly includes at least one of a piezoelectric element and a magnetorestrictive element.
3. The surface communication system of claim 1 , wherein the low power wireless signals are acoustic signals.
4. The surface communication system of claim 1 , wherein the transmitter electronics stores at least one acoustic file indicative of a predetermined command.
5. The surface communication system of claim 1 , wherein the surface communication system further comprises a user input device passing commands to the transmitter electronics, and wherein the transmitter electronics provides the low power signals responsive to receiving the commands.
6. The surface communication system of claim 1 , wherein power levels of the low power signals and the high power signals are predetermined.
7. The surface communication system of claim 1 , wherein the transceiver assembly, the transmitter electronics and the receiver electronics are parts of a cellular telephone.
8. A method comprising the steps of:
programming a surface communication system with at least one instruction to be transmitted to a first wireless modem, the first wireless modem configured to communicate wirelessly with a second wireless modem within a well at a distance in excess of 500 feet;
placing a transceiver assembly of the surface communication system in close proximity to the first wireless modem prior to deployment of the first wireless modem in the well; and
transmitting a low power wireless signal from the transceiver assembly to the first wireless modem including the at least one instruction.
9. The method of claim 8 , wherein programming the surface communication system is defined further as downloading an instruction set to the surface communication system from an external user input device.
10. The method of claim 8 , further comprising the step of installing the first wireless modem within a section of tubing.
11. The method of claim 10 , wherein the step of placing the transceiver assembly in close proximity to the first wireless modem is defined further as placing the transceiver assembly on the section of tubing.
12. The method of claim 8 , wherein the first wireless modem is rigidly mounted within a housing, and wherein the step of placing the transceiver assembly in close proximity with the first wireless modem includes placing the transceiver assembly in contact with a surface of the housing, the housing forming a communication channel to pass the low power wireless signal to the first wireless modem.
13. The method of claim 8 , wherein the low power wireless signal is encoded with an instruction to change a configuration of the first wireless modem from a first state to a second state.
14. The method of claim 8 , wherein the first wireless modem is a part of a downhole tool having electronics separate from the first wireless modem and in communication with the first wireless modem, and wherein the low power wireless signal is encoded with an address of the first wireless modem, and an instruction to change a configuration of the electronics of the downhole tool from a third state to a fourth state.
15. The method of claim 8 , further comprising the step of receiving a confirmation signal from the first wireless modem through stress waves generated by the first wireless modem transmitting acoustic signals.
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EP11290541.9 | 2011-11-24 | ||
EP11290541.9A EP2597491A1 (en) | 2011-11-24 | 2011-11-24 | Surface communication system for communication with downhole wireless modem prior to deployment |
PCT/IB2012/056392 WO2013076620A1 (en) | 2011-11-24 | 2012-11-13 | Surface communication system for communication with downhole wireless modem prior to deployment |
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