WO2016022652A1

WO2016022652A1 - Electro-mechanical-hydraulic instrument bus

Info

Publication number: WO2016022652A1
Application number: PCT/US2015/043765
Authority: WO
Inventors: Homero C. Castillo; Randolph M. COLLINS; Otto N. Fanini
Original assignee: Baker Hughes Incorporated
Priority date: 2014-08-05
Filing date: 2015-08-05
Publication date: 2016-02-11
Also published as: US20160040509A1; EP3177802A1; EP3177802A4

Abstract

A downhole string having a series of downhole tools, where the tools are powered by different energy sources. The different energy sources include electrical, hydraulic, and mechanical. Connections between adjacent downhole tools provide for electrical, hydraulic, and mechanical communication between adjacent tools. Thus energy in one part of the downhole string can be converted into another form of energy and communicated for use in another part of the downhole string.

Description

PCT PATENT APPLICATION

ELECTRO-MECHANICAL-HYDRAULIC INSTRUMENT BUS

Cross-Reference to Related Applications

This application claims priority to and the benefit of U.S. Provisional Application 62/033,468, filed August 5, 2014, and U.S. Non-Provisional Application 14/817,974, filed August 4, 2015, the full disclosure of which is hereby incorporated by reference herein in its entirety for all purposes.

Field of Invention

The present disclosure relates in general to a system and method of delivering one form of energy to a downhole string for powering a tool in the string, and converting the energy to another form for powering another tool in the string.

Description of Prior Art

A wide variety of tools are used in wellbore operations, where the operations typically range from well completions to well intervention. Tools used during well completions and intervention often include perforating tools, logging devices, jars, rollers, tractors, milling tools, cutting tools, expanding tools, setting tools, retrieving tools, bailers, baskets, fishing tools, seismic tools, vacuum cleaners, tubular patching devices, to name a few. These tools are powered by electrical power, hydraulic power, or are mechanical driven. Tools having different sources of power, and with different functionalities and capabilities, are usually deployed downhole at different times (in separate downhole trips) so that a dedicated power source can be provided to the particular downhole tool. Sometimes several different services are conducted when an intervention is performed in a subterranean hydrocarbon producing well installation. However, typically well intervention procedures are designed to undertake one service at a time on separate downhole tripping deployments. Often, the outcome of one service, such as an inspection, a survey, or procedure dictates the next service that is performed. Usually, a particular well service requires a series of operational steps performed by dedicated well intervention tools for each step, which requires that after being used to perform an intervention task, each tool is removed from the wellbore before the next one is tripped downhole. While some intervention tools can be run on the same tool string, currently known tool strings internal power transmission buses are limited in the number of tools they can service at a time requiring separate downhole trip deployments or sequential operational steps within one downhole trip.

Summary of the Invention

Disclosed herein are embodiments of a downhole string and method of using the downhole string in a wellbore. In one example, a downhole string includes an electrically powered tool, a hydraulically powered tool, a mechanically powered tool, a sub between the electrically powered tool and the hydraulically powered tool. The sub includes an electrical connection system having an end in electrical communication with the electrically powered tool and an opposing end in electrical communication the hydraulically powered tool and a hydraulic connection system having an end in hydraulic communication with the electrically powered tool and an opposing end in hydraulic communication the hydraulically powered tool. Further, another sub is included that is between the mechanically powered tool and the electrically powered tool. The another sub is made up of a mechanical connection system having an end mechanically coupled with the mechanically powered tool and an opposing end mechanically coupled with the hydraulically powered tool, and an electrical connection system having an end in electrical communication with the electrically powered tool and an opposing end in electrical communication the mechanically powered tool. The electrically powered tool can be a first electrically powered tool, and the downhole tool can further include a second electrically powered tool and a sub between the second electrically powered tool and the mechanically powered tool. The electrically powered tool can include a device that operates on electricity. The mechanically powered tool can include a device that operates on a mechanical force, mechanical power, or mechanical energy. The hydraulically powered tool can include a device that operates on a supply of hydraulic fluid. In an example, the sub between the electrically powered tool and the hydraulically powered tool includes a housing, a means for connecting the housing to the electrically powered tool, a means for connecting the housing to the hydraulically powered tool; in this example the opposing ends of the electrical connection system are equipped with electrical connectors that selectively connect to electrical connectors in the electrically powered tool and the hydraulically powered tool, and the electrical connectors are in electrical communication via an electrically conducting medium that is disposed in the housing. Further in this example, the opposing ends of the hydraulic connection system have hydraulic connectors that selectively connect to hydraulic connectors in the electrically powered tool and the hydraulically powered tool, and the hydraulic connectors are in hydraulic communication via a hydraulic flow conduit that is disposed in the housing. In an embodiment, the sub between the electrically powered tool and the mechanically powered tool is made up of a cylindrical pressure vessel housing, a means for connecting the housing to the electrically powered tool, a means for connecting the housing to the mechanically powered tool. Alternatively, the opposing ends of the electrical connection system have electrical connectors that selectively connect to electrical connectors in the electrically powered tool and the mechanically powered tool, and the electrical connectors are in electrical communication via an electrically conducting medium that is disposed in the housing, and the opposing ends of the mechanical connection system have mechanical couplings that selectively connect to mechanical couplings in the electrically powered tool and the mechanically powered tool, and the mechanical connectors are mechanically coupled via a mechanical element that is disposed in the housing. In an alternative embodiment, the sub is attached to adjacent ones of the tools with a spin collar that is selectively rotatable with respect to the sub and threadingly affixed to the adjacent ones of the tools.

Also disclosed herein is an example of a downhole string for use in a wellbore that includes a pair of downhole tools and a sub connected between the downhole tools that inlcudes two or more of (1 ) an electrical connection system through which the pair of downhole tools are in electrical communication, (2) a mechanical connection system through which the pair of downhole tools are mechanically coupled, and (3) a hydraulic connection system through which the pair of downhole tools are in hydraulic communication. The downhole string can further include another downhole tool, wherein the pair of downhole tools and the another downhole tool have an electrically powered tool, a hydraulically powered tool, and a mechanically powered tool. In an example, the sub is a first sub, wherein the downhole string further includes a second sub, and wherein a one of the first and second sub is disposed between the pair of downhole tools, and wherein the other one of the first and second sub is disposed between the pair of downhole tools and the another downhole tool. The first sub has the electrical connection system and the mechanical connection system, so that when the first sub is connected between the electrically powered tool and the mechanically powered tool, electrical and mechanical power is transferred between the electrically powered tool and the mechanically powered tool via the first sub. In one example, the first sub includes the electrical connection system and the hydraulic connection system, so that when the first sub is connected between the electrically powered tool and the hydraulically powered tool, electrical and hydraulic power is transferred between the electrically powered tool and the hydraulically powered tool via the first sub.

Further disclosed herein is an example method of using a downhole string in a wellbore and which includes providing a first form of energy to the downhole string in the wellbore, operating a downhole tool in the downhole string with the first source of energy, and converting the first form of energy to a second form of energy and operating another downhole tool in the downhole string with the second form of energy. In an embodiment, the downhole tool is a first downhole tool and the another downhole tool is a second downhole tool, in this embodiment the method further includes converting one of the first form of energy or the second form of energy to a third form of energy, and operating a third tool in the downhole string with the third form of energy. Alternatively connectors are provided in the downhole string for communicating forms of energy between adjacent downhole tools, plus transfer across the tool string of command , sensor and operational state data, and control functionality. The forms of energy communicated between the downhole tools can be two of more of electrical energy, hydraulic energy, and mechanical energy. In an alternative, the downhole tool and the another downhole tool are operated simultaneously. Energy storage could be implemented with the supply of another source of energy form. Optionally, the another downhole tool is operated a time that is different than a time when the downhole tool is operated. In an example of operation, the downhole tool and the another downhole tool are coupled to one another proximate the wellbore. Brief Description of Drawings

Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a partial side sectional view of an example of a downhole string disposed in a wellbore.

FIG. 2 is an axial view of an electrical connector for use in the downhole string of

FIG. 1.

FIG. 3 is an axial view of an electrical-mechanical connector for use in the downhole string of FIG. 1.

FIG. 4 is an axial view of an electrical-hydraulic connector for use in the downhole string of FIG. 1.

FIG. 5 is an axial view of a mechanical-hydraulic connector for use in the downhole string of FIG. 1.

FIG. 6 is an axial view of a mechanical-hydraulic-electrical connector for use in the downhole string of FIG. 1.

FIG. 7 is a partial side sectional view of an alternate example of a downhole string disposed in a wellbore.

FIG. 8 is a side sectional view of an example of an electrical-mechanical-hydraulic connector for use with a downhole string. While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.

Detailed Description of Invention

The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term "about" includes +/- 5% of the cited magnitude. In an embodiment, usage of the term "substantially" includes +/- 5% of the cited magnitude.

It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.

Figure 1 shows in a partial side sectional view an example of a tool string 10 disposed within a wellbore 12, where the wellbore intersects a subterranean formation 14. The tool string 10 is deployed on a wireline 16, which in one example can provide electrical power as well as data signals to the tool string 10. Schematically illustrated in dashed outline is an instrument bus 17 that extends along the length of the tool string 10. As described in more detail below, the instrument bus 17 provides for a seamless transfer of one or more of mechanics, hydraulics, and electricity throughout the entirety of the tool string 10 so that devices that operate mechanically, hydraulically, or electrically in the string 10 can be appropriately powered. In an example, mechanics includes mechanical force, power, energy, or a combination thereof, and which is used to drive or power a device that operates in response to a mechanical input. In an example, transfer of mechanics takes place via a member, such as a shaft, that is rotatable or axially moveable. Examples of hydraulics include any type of fluid usable for operating a downhole tool. A surface truck 18 is shown above the opening of the wellbore 12 and on surface 19, wherein the surface truck 18 may include controllers (not shown) for providing control signals for operating a downhole string 10. Optionally, a power source (not shown) can be provided for providing electrical power through the wireline 16 into the downhole string 10. Placement of the power source can be on surface, within surface truck 18, or downhole. A wellhead assembly 20 is shown covering the opening of wellbore 12 and on surface 19. The wireline 16 threads through the wellhead assembly 20.

The downhole string of Figure 1 is made up of a series of downhole tool units 22, 24, 26, 28, 30, 32, 34. The downhole tool units 22, 24, 26, 28, 30, 32, 34 can each perform the same function, can perform different functions, or more than one of the units 22, 24, 26, 28, 30, 32, 34 can perform the same function, while the remaining ones can perform different functions. In an alternative, the downhole tool units 22, 24, 26, 28, 30, 32, 34 can each include one or more distinct downhole tools, and thus the string 10 can make up a mixture of different types of tools performing different functions. In one alternate embodiment, the downhole tools of the tool string 10 are powered by different forms of energy. In an example, different forms of energy include electrical, hydraulic, pneumatic, mechanical, combinations thereof, and the like. Thus in an example of operation, a function involving one or more of the types of powering (i.e. mechanics, electrical, hydraulic) can be performed at one depth, then the tool moved to another depth in the wellbore and another function can be performed involving a different type of powering than what was performed at the previous depth.

Schematically represented within tool string 10 are connectors 36, 38, 40, 42, 44, 46, 48 between adjacent ones of the units 22, 24, 26, 28, 30, 32, 34. In the example of Figure 1, connector 36 provides electrical and mechanical connection between the tool string 10 and wireline 16. The remaining connectors are between adjacent ones of the downhole tools and as described in more detail below perform connectivity functions of energy between adjacent ones of the downhole tools.

An optional controller 50 is shown in downhole tool 22 and can be used for controlling operations within or by downhole tool unit 22, or any of the other downhole tool units 24, 26, 28, 30, 32, 34. In an example, controller 50 includes an information handling system (IHS), which can store recorded data as well as process the data into a readable format. The IHS may be disposed at the surface, in the wellbore, or partially above and below the surface. In an example, the IHS includes one or more of a processor, memory accessible by the processor, nonvolatile storage area accessible by the processor, and logics for performing each of the steps above described. Further shown in dashed outline is a motor 52 disposed within downhole tool unit 22, where motor 52 can be run on electrical power delivered by wireline 16. A shaft 54 (shown in dashed outline) has an end that couples with an output of motor 52, and on its other end connects to a pump 55 for driving pump. In one example, pump 55 pressurizes hydraulic fluid which may be stored in a reservoir 56, which is shown in dashed outline in downhole tool 24 and adjacent pump 55. As will be described in more detail below, examples exist where pressurized fluid in reservoir 56 is used for powering one or more of the units 22, 24, 26, 28, 30, 32, 34.

Figure 2 shows an axial view of an example of an electrical connector 58, which in an embodiment provides transfer of electrical energy between adjacent ones of the downhole tool units 22, 24, 26, 28, 30, 32, 34 described above. Electrical connector 58 is shown having an outer and circular housing 60, extending axially within housing 60 are a series of electrical lines 62. In the example, lines 62 are arranged proximate an inner surface of housing 60 and spaced radially away from an axis Αχ of string 10 (Figure 1). Electrical fittings or couplers (not shown) can be attached on terminal ends of the lines 62 for connection of the lines 62 to other lines or to equipment powered by electrical power, i.e. motors, sensors, controllers, etc.

Referring now to Figure 3, depicted in an axial sectional view is an example of an electrical-mechanical connector 64, which is shown having an outer circular housing 66. Oriented axially within housing 66 are electrical lines 62 and a shaft coupling 68. In the example of Figure 3, shaft coupling 68 is used for mechanically connecting mechanical means within adjacent downhole tools, i.e. shafts, gears, cams, rods, and the like. In the illustrated example, coupling 68 includes an elongate member with splines extending axially along its outer surface for engaging with couplings (not shown) in a one of the units 22, 24, 26, 28, 30, 32, 34 having complementary spline profiles in which shaft coupling 68 is selectively inserted. Further in the example, coupling 68 has an opposing end (not shown) configured to engage ends of shafts within the adjacent downhole tools. In an alternative, the opposing end is equipped with a female fitting configured to receive a male type fitting similar to coupling 68. However, coupling 68 can be any type of device for a mechanical transfer between adjacent tools. The mechanical transfer can include one or more of mechanical force, axial motion, rotational motion, mechanical power, or mechanical energy.

Figure 4 illustrates in an axial sectional view an example of an electrical-hydraulic connector 70; which is also shown set within a circular housing 72. In this example, a series of hydraulic lines 73 extend axially through housing 72 and are accompanied by a series of electrical lines 62. Thus, the electrical -hydraulic connector 70 of Figure 4 can provide for connectivity of electricity and hydraulics between adjacent downhole tools. In an example, hydraulic couplers (not shown) are provided on the terminal ends of the hydraulic lines 73 for connection to hydraulic lines (not shown) in a one of the units 22, 24, 26, 28, 30, 32, 34, Hydraulic couplers can be of any known or later developed type for connecting together ends of lines carrying fluids. In an example, fluid is conveyed between adjacent tools in a downhole string via the hydraulic couplers.

Shown in an axial cross sectional view in Figure 5 is one example of a mechanical hydraulic connector 74 for mechanical and hydraulic transfer between adjacent tools in a downhole string. Connector 74 includes hydraulic lines 73, and can optionally include a hydraulic coupler with the lines for attaching to hydraulic lines in the adjacent tools. An example of a shaft coupling 68 is further illustrated in connector, and similar to connector 64 can provide a means for mechanical transfer between adjacent tools. A housing 75 is shown providing an outer cover for the components within connector 74.

Figure 6 is an axial sectional view of one example of an electrical mechanical hydraulic connector 76, and across which mechanical, hydraulic, and electrical transfer can take place between adjacent tools in a downhole string. Included with connector 76 are electrical lines 62, hydraulic lines 73, and a shaft coupling 68. Similar to connectors 70, 74, hydraulic couplers can be included for connecting hydraulic lines 73 to components or lines in tools engaged with the ends of the connector 76.

Embodiments exist where one or more of connectors 58, 64, 70, 74, 76 are "field joints", which can be selectively detached from an adjacent tool so that any tools joined by the field joint can be decoupled from one another with relative ease. Moreover, field joints can be coupled to or decoupled from another member, such as a downhole tool, in the field proximate a well site and without the need to return the assembly to a shop. In an embodiment, the field joints are equipped with a spin collar so that neither the tools nor the field joints are rotated when being coupled to one another. In contrast, a maintenance joint is not intended to be dismantled in the field. Optionally, each of the connectors 58, 64, 70, 74, 76 can be equipped with guide pins or slots (not shown) to facilitate alignment when being assembled within the tool string 10.

Referring back to Figure 1 , as indicated above, connector 36 provides electrical connectivity between wireline 16 and string 10, and thus in this example has the form of the electrical connector 58 of Figure 2. In another example, downhole tool unit 22 is made up of a number of tools; wherein as shown each adjacent tool within downhole tool unit 22 is connected together with electrical-mechanical connector 64 of Figure 3. In one example, the upper most tool within downhole tool unit 22 can be a cutting tool, a milling tool, or any other electrically powered mechanical device. Accordingly, connectors 36, 38, 40, 42, 44, 46, 48 can used for connecting or coupling together downhole tools provided within the units 22, 24, 26, 28, 30, 32, 34. Moreover, in one example, the combination of the connectors 36, 38, 40, 42, 44, 46, 48, electrical and hydraulic lines and shafts or rods (not shown) in the units 22, 24, 26, 28, 30, 32, 34, make up the instrument bus 17. Optionally, the wireline 16 can also be considered as part of the instrument bus 17.

Further in example of Figure 1, connector 40 is an electrical-hydraulic connection 70, such as that illustrated in Figure 4, and which may transfer energy in the form of electricity and pressurized hydraulic fluid between tool unit 26 and tool unit 24. Similar to tool units 22 and 24, tool unit 26 may include multiple tools within. One example of tool within tool unit 26 can be one which takes the pressurized hydraulic fluid and converts it to rotational energy and which can be used for driving mechanical devices disposed within tool unit 26. Additionally, due to the electrical lines 62 and connector 70, tool unit 26 may include electrically powered tools, such as cutting and milling machines as well as submersible pumps.

Optionally, connector 44 is an electrical connector, such as electrical connector 58 in Figure 2, so that tools within tool unit 30 are driven specifically by electrical power transferred along the bus formed by the series of connectors 36, 38, 40, 42 that are disposed in tool string 10 and above connector 44. In the illustrated embodiment, connector 46 is an electrical-mechanical connection, such as connector 64, in Figure 3. Optionally, therefore tools within tool unit 32 may include a pump which is for pressurizing hydraulic fluid that is selectively stored within tool unit 32 for driving other tools within tool string 10; or alternatively cool down and lubricate mechanically moving parts, gears, motors (electrical or hydraulic) and actuators (mechanical, electrical, or hydraulic). Thus in this example tool unit 32 includes a reservoir (not shown). In this alternative, connector 48 is an electrical-hydraulic connector, such as connector 70 in Figure 4 and so that electrical and hydraulic forms of energy can be coupled between tool unit 32 into tool unit 34. Accordingly, one significant advantage of tool string 10 described herein is that during a single trip downhole, multiple types of intervention may take place in wellbore 12 and without removing the tool. The ability to convert between different forms of energy within the tool, and transfer those forms of energy between adjacent tool units, provides this enhanced feature of the tool string 10 described herein.

In alternative embodiments, tool unit 24 may include tools involved in well intervention, such as logging tools used for logging wellbore 12, as well as tools having batteries and PCL. Alternatively, tool unit 26 can include tools such as releasable jars, rollers and tools that perform real time monitoring and control of operation and which can be reprogramed, have functional control and artificial intelligence. Tool unit 28 can include tools which have real time servo control, control power consumption and distributions, control power load spikes, voltage and control management, and regulate power voltage, perform sequencing and timing of power distribution, and have supplemental power generation. In one example, included is a power management system executed from the surface 19, or in coordination with downhole tool string controllers, adjusts the operational execution so that tools in the string do not exceed maximum mechanical stress allowed and also maximum energy available for deliver targeted work execution. Moreover, tools in tool unit 28 may include mud pumps and any other device that converts kinetic motion derived energy such as in a rotating shaft or pressurized fluid motion (including mechanical or hydraulic energy) to electrical energies. In this example, the source energy could be pressurized hydraulic fluid. Example tools within tool unit 30 include downhole tractors, milling tools, cutting tools, expanding tools, setting tools (such as inflatable packers), include valves for retrieving and setting, include power jars, include bailers, baskets, fishing tools, downhole seismic and logging devices, perforating guns, gear reducers, electrical and hydraulic perforators and drillers, oriented tubing punchers, vacuum cleaners and basket retrieval debris, casing and tubing patch devices, and piston drivers. Optics may be included with the string 10 so that a component downhole (such as a tubular) can be viewed real time by operations personnel on surface as downhole operations (such as cutting through the tubular) are taking place. Also included in tool unit 30 are tool joint clutches, electrical backup to mechanical-hydraulic, tools within tool unit 32 may be anti-rotating tool joints as well as single run interventions tool. Tool unit 34 can include multiple tractors. It should be pointed out that the unique method of transferring mechanics, hydraulics, and electricity as illustrated in Figure 1 allows for an unlimited combinations of arrangements of units 22, 24, 26, 28, 30, 32, 34. Moreover, a tool string 10 can have any type of unit (i.e. operational by mechanics, hydraulics, or electricity) be included and powered on the tool string 10 as each of mechanics, hydraulics, or electricity can be transferred to adjacent units or generated with one or more of the other forms of powering. Also, a unit powered by one or more of mechanics, hydraulics, or electricity can be put into a selected position in the string 10 by virtue of strategically providing an appropriate one of the connectors 58, 64, 70, 74, 76. Additionally, some of the units 22, 24, 26, 28, 30, 32, 34 may be operationally powered and enabled; while at the same time some of the other units 22, 24, 26, 28, 30, 32, 34 are not powered nor operational. In an example, selective powering of the units 22, 24, 26, 28, 30, 32, 34 is performed by controller 50. Any of the units 22, 24, 26, 28, 30, 32, 34 can include tools or devices for evaluation formation, well integrity, well construction, and production and completion installation.

In an example method of operation, controller 50 executes and delivers a variety of service solutions primarily delivered mechanically but powered in multiple modes and field tool string stack up sequence. Optionally, limited power available is required designing the service execution with sequential and concurrent steps. The device can be deployed in a well, locate a target, position the string 10 correctly, clean casing C, cut a casing window W, remove cutting debris, insert plug P, seal, test and finish, next service, to name but a few. Optionally included is a surface to downhole feedback control loop with a stabilizing and power management algorithm using power load levels sensing (string composite use and each network node) and telemetry metering and surface to downhole power management communication and feedback control algorithms (main power control loop). A Downhole Remote Master controller (not shown) may also be included that performs a local downhole power management algorithm with feedback control (dependent slave control loop) involving all and each bus node to make sure downhole power consumption does not exceed power available from the surface at each moment and each service operational step. Examples of energy conversion modules are shown in the figures. Optionally included is a backbone internal communication bus (not shown) with sub-network protocol (OSI model) coordinating the service with the downhole remote master controller and each service node and also coordinating the operational, safety and parametric aspects of the one-trip delivery of a variety of services (independent or complementary).

Referring now to Figure 7, shown is a partial sectional view of an alternate example of a tool string 10A in wellbore 12. As shown, downhole tool unit 22 includes a power sub 78, a first electro-mechanical tool (first EM tool) 79, and a second electro-mechanical tool (second EM tool) 80. Connectors 82, 84 respectively connect power sub 78 to first EM tool 79, and first EM tool 79 to second EM tool 80. In the example of Figure 7 connectors 82, 84 are substantially similar to electrical-mechanical connector 64 (Figure 3). Controller 50 and motor 52 are housed in power sub 78. Connector 38 is shown mounted to an end of second EM tool 80 distal from connector 84 and provides connection and energy communication from second EM tool 80 to downhole tool unit 24. Downhole tool unit 26 of tool string 10A includes a first electro-hydraulic tool (first EH tool) 86 and a second electro-hydraulic tool (second EH tool) 88, and which are connected via a connector 90. Connector 90 communicates electrical and hydraulic fluid between first EH tool 86 and second EH tool 88, and thus in the example of Figure 7 connector 90 is the same or substantially similar to connector 70 (Figure 4). Further illustrated in the embodiment of Figure 7 is that downhole tool unit 28 includes a third electro-mechanical tool (third EM tool) 92 and a fourth electro-mechanical tool (fourth EM tool) 94 that are coupled to one another via connector 96. In the example third EM tool 92 and fourth EM tool 94 are in electrical and mechanical communication, thus connector 96 is the same or substantially similar to connector 64 (Figure 3).

Still referring to Figure 7, downhole tool unit 30 includes first and second electric tools 98, 100, that are connected to one another by connector 102. As first and second electric tools 98, 100 are in electrical communication, connector 102 is the same or substantially similar to connector 58 (Figure 2). Schematically illustrated within second electric tool 100 are a controller 104 (that selectively controls operations of components within the string 10A), and a motor 106. In an example motor is electrically powered, such as by electricity supplied by wireline 16, and that is transferred down the string 10A by the connectors included in the string. Motor 106 includes an output shaft shown terminating in a connector 1 10 on an end of second electric tool 100 distal from connector 102. Connector 1 10 provides coupling and energy transfer between second electric tool 100 and downhole tool unit 32, which is shown engaged with an end of connector 110 distal from second electric tool 100. Another shaft 112 is shown disposed in downhole tool unit 32 and projecting from the end of connector 1 10 distal from second electronic tool 100. In the example of Figure 7, connector 1 10 is the same or substantially similar to connector 64 (Figure 3). An end of shaft 1 12 distal from connector 1 10 connects to a pump 1 14 schematically illustrated within downhole tool unit 32. Also shown within downhole tool unit 32 is a reservoir 1 16 for receiving and storing fluid pressurized by pump 1 14. Thus by energizing motor 106 pump 1 14 can be activated (via shafts 108, 1 12 and connector 1 10), to pressurize hydraulic fluid for delivery to the reservoir 116. The pressurized fluid in reservoir 1 16 can be used to perform various downhole functions.

A side sectional view of an example of a connector 120 is provided in Figure 8, where electricity/signals, hydraulics, and mechanics are communicated across connector 120. As shown, connector 120 includes a substantially cylindrically shaped body 122 whose outer diameter transitions to accommodate coupling with a downhole tool 124. In the illustrated embodiment, downhole tool 124 is one of the above described tools, and thus can include devices powered by electricity, mechanics, hydraulics, or any combination thereof Examples exist wherein the connector 120 and tool 124 are part of a downhole string, such as string 10 of Figure 1 or string 10A of Figure 7. In an embodiment of this example, an end of connector 120 distal from tool 124 connects to a downhole tool (not shown) or another connector, whereas an end of tool 124 distal from connector 120 connects to another connector or tool (not shown), or can define an end of tool string 10, 10A. An annular spin collar 126 is shown circumscribing a portion of body 122 proximate to downhole tool 124. Spin collar 126 is rotatable with respect to body 122 and has a lip 128 shown protruding radially inward and which inserts into a recess 130 formed into an outer surface of body 122. Recess 130 has a finite axial distance thereby affixing lip 128 and collar 126 to body 122 and limiting axial movement of collar 126 with respect to body 122. An end of collar 126 distal from lip 128 circumscribes a portion of tool 124 proximate body 122. Threads 132 are formed on an inner surface of collar 126 that faces an outer surface of tool 124. Selectively rotating collar 126 engages threads 132 with threads 133 shown formed on an outer surface of tool 124, thereby coupling connector 120 to tool 124. A cavity 134 is shown provided axially within an end of tool 124 facing connector 122, and which receives an end of connector 122. O-rings 136 are illustrated set in recesses 137 formed on an outer surface of body 122, and which define a sealing interface between body 122 and a sidewall of cavity 134. Signal lines 138, 139 are shown extending axially through body 122 and spaced radially apart from one another. In an example, signal lines 138, 139 are formed from an electrically conducting material, across which electricity and or signals are transmitted. Alternatively, one or both of signal lines 138, 139 include fiber optical material that transmits optical signals. As shown, signal lines 138, 139 respectively connect to receptacles 140, 141 that are disposed at a terminal end of body 122 adjacent tool 124. Male connectors 142, 143 are shown mounted in a bottom of cavity 134 and that have portions that project axially from the bottom of cavity 134 and respectively into electrical connection with receptacles 140, 141. Signal lines 144, 145 connect respectively to connectors 142, 143, and extend axially through tool 124 and that are spaced radially apart from one another. Similar to signal lines 138, 139, in one embodiment signal lines 144, 145 are formed from an electrically conducting material; or alternatively, one or both of signal lines 144, 145 include fiber optical material that transmits optical signals. Accordingly, signal lines 138, 139 are in signal communication with signal lines 144, 145 via engagement of receptacles 140, 141 to connectors 142, 143.

Also shown in the example of Figure 8 are hydraulic lines 146, 147 that extend axially within body 122 and disposed radially apart from one another. The ends of lines 146, 147 proximate tool 124 connect to female hydraulic couplers 148 , 149 set in the terminal end of body 122 that inserts into cavity 134. Female hydraulic couplers 148, 149 engage male hydraulic couplers 150, 151 shown mounted in the radial surface of cavity 134 when the connector 120 connects with downhole tool 124. Hydraulic lines 152, 153 are illustrated extending axially through tool 124 and spaced radially apart, hydraulic lines 152, 153 respectively connect to the ends of male hydraulic couplers 150, 151 that are opposite ends that connect to female hydraulic couplers 148, 149. Thus lines 146, 147 are in selective communication with lines 152, 153 through connection of female hydraulic couplers 148, 149 with male hydraulic couplers 150, 151. Pins 154, 155 in the male hydraulic couplers 150, 151 project axially into the female hydraulic couplers 148, 149 and engage check valves 156, 157 disposed in the female hydraulic couplers 148, 149 to open communication across the female hydraulic couplers 148, 149. Insertion of pins 154, 155 into the check valves 156, 157 opens the check valves 156, 157 so that fluid can lines 146, 147 can communication with lines 152, 153. It should be pointed out that a single signal line or hydraulic line, or more than two signal or hydraulic lines can be included in the connector 120 and tool 124. An example of the hydraulic coupler can be obtained at http://www, staubli.com/.

In addition to the transfer of electricity and hydraulics between connector 120 and tool 124, mechanics can be transferred between connector 120 and tool 124 via connector 120. An example of a selectively rotatable shaft 160 is depicted axially extending through body 122 and which is couples with a selectively rotatable shaft 162 that axially extends within tool 124. A mechanical coupler 164 rotationally engages shafts 160, 162 to one another. Coupler 164 of Figure 7 includes a pin 166 that axially inserts into a receptacle 168 formed into an end of shaft 160 facing shaft 162. Splines 169, 170 are formed respectively in the pin 166 and receptacle 168 that are in angular interference with one another to rotationally couple the shaft and pin 166. Optionally, threads 171 can be employed for engaging the shaft 160 and pin 166. A U-joint 172 is shown coupling the pin 166 with shaft 162, so that pin 166 can pivot with respect to shaft 162 and account for any misalignment that may take place between the respective shafts 160, 162. Recesses 174, 176 are shown extending axially and radially along an interface where the end of body 122 inserts into cavity 134. A key 178 inserts into recesses 174, 176, recesses 174, 176 are not annular but extend along only a portion of the circumference of axis Αχ. As such, the presence of the key 178 limits rotation of connector 120 with respect to tool 124. Moreover, key 178 can azimuthally align connector 120 to tool 124 so that connectors 142, 143 can register with receptacles 140, 141 , and so that male hydraulic couplers 150, 151 can register with female hydraulic couplers 148, 149. Bearings 180, 182, that are depicted as roller bearings, are optionally provided to reduce frictional resistance to rotation of shafts 160, 162 within body 122 and tool 124. Alignment shoulders 184, 186 are provided between the sets of bearings 180, 182. Optionally, seals 188, 190 are provided around shafts 160, 162 that define fluid flow barriers axially along the outer surfaces of the shafts 160, 162.

Referring back to the example of Figure 1, downhole controller 36 (or controllers associated with each of the tools of the string 10, 10A) can receive commands from the surface or be pre-programmed at the surface 19 or re-programmed to control, monitor and coordinate one or a multitude of operational steps performed downhole sequentially or simultaneously. Further in this example, sensors and timers are used by controller 36 to determine operational state and progress ( relative, combination of or absolute for the following sensor readings: position, RPM. pressure, volume, angular movement, angular speed, tension, compression, torsion, vibration, temperature, etc.) and provide feedback control to a control loop executing a prescribed operational step sequence and maintaining within limits operational states, conditions and state or value relationships. Surface controller (not shown), which can be set in surface truck 18, supervises downhole controller 36 which detects, analyzes and adapts to specific well structure and downhole operational conditions to operational adjust task execution, timing and sequence well considering power, relative position and size of tool string versus well installation characteristics and dimensions plus other constraints such as well and tool string physical limitations structural integrity, materials strength, etc. A downhole adaptive decision criteria and control parameter could involve at least a casing integrity evaluation tool data, formation evaluation data, production logging tool data, installation functionality testing evaluation data, production installation performance spec data, aging, wear and corrosion to derive equipment life-time replacement scheduling, for example. The downhole operation can have different levels of automation ranging from manually controlled step by step, semi-automated or fully automated. Tool string 10 could have one central controller or various controllers controlling operations in coordination with other controllers supervised by a surface controller. Power, data, control, communication can be transferred via different energy forms such as electrical (or via electromagnetic waves), mechanical, hydraulic, etc.

The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, tools within the tool units can be run on the same form of energy, or one of connectors 58, 64, 70 can be included within a tool unit so that tools within a tool unit can operate on different forms of energy. Optionally, each of the tools of Figure 7 may include a dedicated controller (not shown) within the tool, where these controllers can optionally communicate with controller 50 or surface truck 18 (Figure 1). In an alternative embodiment, each of the connectors between adjacent tool units or between adjacent tools is an electrical-hydraulic- mechanical connector, even though adjacent tool units or tools do not consume or require each of electricity, hydraulics, and mechanics for operation or control. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.

Claims

Claims What is claimed is:

1. A downhole string for use in a wellbore comprising: an electrically powered tool; a hydraulically powered tool; a mechanically powered tool; a sub between the electrically powered tool and the hydraulically powered tool comprising, an electrical connection system having an end in electrical communication with the electrically powered tool and an opposing end in electrical communication the hydraulically powered tool, and a hydraulic connection system having an end in hydraulic communication with the electrically powered tool and an opposing end in hydraulic communication the hydraulically powered tool; and a sub between the mechanically powered tool and the electrically powered tool comprising, a mechanical connection system having an end mechanically coupled with the mechanically powered tool and an opposing end mechanically coupled with the hydraulically powered tool, and an electrical connection system having an end in electrical communication with the electrically powered tool and an opposing end in electrical communication the mechanically powered tool.

2. The downhole string of Claim 1, wherein the electrically powered tool comprises a first electrically powered tool, the downhole tool further comprising a second electrically powered tool and a sub between the second electrically powered tool and the mechanically powered tool.

3. The downhole string of Claim 1 , wherein the electrically powered tool comprises a device that operates on electricity.

4. The downhole string of Claim 1, wherein the mechanically powered tool comprises a device that operates on a mechanical force.

5. The downhole string of Claim 1 , wherein the hydraulically powered tool comprises a device that operates on a supply of hydraulic fluid.

6. The downhole string of Claim 1 , wherein the sub between the electrically powered tool and the hydraulically powered tool comprises a housing, a means for connecting the housing to the electrically powered tool, a means for connecting the housing to the hydraulically powered tool, wherein the opposing ends of the electrical connection system comprise electrical connectors that selectively connect to electrical connectors in the electrically powered tool and the hydraulically powered tool, and the electrical connectors are in electrical communication via an electrically conducting medium that is disposed in the housing, and wherein the opposing ends of the hydraulic connection system comprise hydraulic connectors that selectively connect to hydraulic connectors in the electrically powered tool and the hydraulically powered tool, and the hydraulic connectors are in hydraulic communication via a hydraulic flow conduit that is disposed in the housing.

7. The downhole string of Claim 1, wherein the sub between the electrically powered tool and the mechanically powered tool comprises a housing, a means for connecting the housing to the electrically powered tool, a means for connecting the housing to the mechanically powered tool wherein the opposing ends of the electrical connection system comprise electrical connectors that selectively connect to electrical connectors in the electrically powered tool and the mechanically powered tool, and the electrical connectors are in electrical communication via an electrically conducting medium that is disposed in the housing, and wherein the opposing ends of the mechanical connection system comprise mechanical couplings that selectively connect to mechanical couplings in the electrically powered tool and the mechanically powered tool, and the mechanical connectors are mechanically coupled via a mechanical element that is disposed in the housing.

8. The downhole string of Claim 1 , wherein the sub is attached to adjacent ones of the tools with a spin collar that is selectively rotatable with respect to the sub and threadingly affixed to the adjacent ones of the tools.

9. A downhole string for use in a wellbore comprising: a pair of downhole tools; and a sub connected between the downhole tools that comprises two or more of: an electrical connection system through which the pair of downhole tools are in electrical communication, a mechanical connection system through which the pair of downhole tools are mechanically coupled, and a hydraulic connection system through which the pair of downhole tools are in hydraulic communication.

10. The downhole string of Claim 9, further comprising another downhole tool, wherein the pair of downhole tools and the another downhole tool comprise an electrically powered tool, a hydraulically powered tool, and a mechanically powered tool.

1 1. The downhole string of Claim 10, wherein the sub comprises a first sub, wherein the downhole string further comprises a second sub, and wherein a one of the first and second sub is disposed between the pair of downhole tools, and wherein the other one of the first and second sub is disposed between the pair of downhole tools and the another downhole tool.

12. The downhole string of Claim 11 , wherein the first sub comprises the electrical connection system and the mechanical connection system, so that when the first sub is connected between the electrically powered tool and the mechanically powered tool, electrical and mechanical power is transferred between the electrically powered tool and the mechanically powered tool via the first sub.

13. The downhole string of Claim 1 1 , wherein the first sub comprises the electrical connection system and the hydraulic connection system, so that when the first sub is connected between the electrically powered tool and the hydraulically powered tool, electrical and hydraulic power is transferred between the electrically powered tool and the hydraulically powered tool via the first sub.

14. A method of using a downhole string in a wellbore comprising: providing a first form of energy to the downhole string in the wellbore; operating a downhole tool in the downhole string with the first source of energy; and converting the first form of energy to a second form of energy and operating another downhole tool in the downhole string with the second form of energy.

15. The method of Claim 14, wherein the downhole tool comprises a first downhole tool and the another downhole tool comprises a second downhole tool, the method further comprising converting one of the first form of energy or the second form of energy to a third form of energy, and operating a third tool in the downhole string with the third form of energy.

16. The method of Claim 14, wherein connectors are provided in the downhole string for communicating forms of energy between adjacent downhole tools.

17. The method of Claim 16, wherein the forms of energy communicated between the downhole tools comprise two of more of electrical energy, hydraulic energy, and mechanical energy.

18. The method of Claim 17, wherein the downhole tool and the another downhole tool are operated simultaneously.

19. The method of Claim 14, wherein the another downhole tool is operated a time that is different than a time when the downhole tool is operated.

20. The method of Claim 14, wherein the downhole tool and the another downhole tool are coupled to one another proximate the wellbore.