DOWNHOLE TELEMETRY TOOL WITH ADAPTIVE FREQUENCY TRANSMITTER
20170268331 · 2017-09-21
Inventors
- Gavin Gaw-Wae Lee (Calgary, Alberta, CA)
- Justin C. Logan (Calgary, Alberta, CA)
- Kurtis West (Calgary, Alberta, CA)
- Luke Stack (Calgary, Alberta, CA)
- Aaron W. Logan (Calgary, Alberta, CA)
Cpc classification
E21B47/24
FIXED CONSTRUCTIONS
International classification
Abstract
A method for selecting a drilling fluid pressure pulse transmission frequency in a downhole telemetry tool comprises: emitting a frequency sweep wave in a drilling fluid that comprises pressure pulses over a range of frequencies and over a period of time; measuring a pressure of the drilling fluid at the telemetry tool while the frequency sweep wave is being emitted; determining a signal strength at each frequency in the range of frequencies from the measured pressure of the drilling fluid; and selecting at least one frequency in the range of frequencies that meets a selected signal strength threshold as a telemetry signal transmission frequency for the telemetry tool. The method can further comprise encoding the at least one selected frequency in a header message and transmitting the header message to surface using pressure pulse telemetry, and then encoding telemetry data into a pressure pulse telemetry signal and transmitting the pressure pulse telemetry signal to surface at the at least one selected frequency.
Claims
1. A method for selecting a drilling fluid pressure pulse transmission frequency in a downhole telemetry tool, comprising: (a) emitting a frequency sweep wave in a drilling fluid, comprising pressure pulses over a range of frequencies and over a period of time; (b) measuring a pressure of the drilling fluid at the telemetry tool while the frequency sweep wave is being emitted; and (c) determining a signal strength at each frequency in the range of frequencies from the measured pressure of the drilling fluid, and selecting at least one frequency in the range of frequencies that meets a selected signal strength threshold as a telemetry signal transmission frequency for the telemetry tool.
2. A method as claimed in claim 1 further comprising after (c): (d) encoding the at least one selected frequency in a header message and transmitting the header message to surface using pressure pulse telemetry.
3. A method as claimed in claim 2 further comprising after (d): (e) encoding telemetry data into a pressure pulse telemetry signal and transmitting the pressure pulse telemetry signal to surface at the at least one selected frequency.
4. A method as claimed in claim 3 further comprising receiving measurement-while-drilling (MWD) sensor data and determining drilling conditions from the MWD sensor data, then selecting a time period to emit the frequency sweep wave based at least in part on the determined drilling conditions.
5. A method as claimed in claim 3 further comprising emitting the frequency sweep wave during a drill string idle time or when the drilling fluid is flowing but the telemetry tool is not transmitting any telemetry signals.
6. A method as claimed in claim 1 wherein the frequency sweep wave comprises a range of frequencies between 1 Hz and a maximum operating frequency of the telemetry tool.
7. A method as claimed in claim 1 wherein the step of determining the signal strength at each frequency in the range of frequencies comprises applying a time-frequency analysis to the measured pressure of the drilling fluid.
8. A method as claimed in claim 7 wherein the time-frequency analysis is selected from a group consisting of: Fourier transforms, wavelet analysis, and fast orthogonal search.
9. A method as claimed in claim 1 wherein the step of determining the signal strength at each frequency in the range of frequencies comprises determining a noise component at each frequency in the range of frequencies and selecting at least one frequency having a signal-to-noise ratio that meets a minimum signal-to-noise ratio threshold.
10. A downhole telemetry tool for transmitting a pressure pulse telemetry signal in a drilling fluid, comprising: (a) a pressure pulse generator operable to generate pressure pulses in a drilling fluid over a range of frequencies; (b) a pressure transducer operable to measure a pressure of the drilling fluid at the telemetry tool; (c) a controller communicative with the pressure pulse generator and the pressure transducer, and comprising a processor and a memory having stored thereon program code executable by the processor to perform a transmission frequency selection operation comprising: (i) instructing the pressure pulse generator to emit a frequency sweep wave in the drilling fluid that comprises pressure pulses over a range of frequencies and over a period of time; (ii) reading pressure measurements from the pressure transducer while the frequency sweep wave is being emitted; and (iii) determining a signal strength at each frequency in the range of frequencies from the measured pressure of the drilling fluid, and selecting at least one frequency in the range of frequencies that meets a selected signal strength threshold as a telemetry signal transmission frequency for the telemetry tool.
11. A downhole telemetry tool as claimed in claim 10 wherein the pulse generator comprises a rotor and stator valve mechanism.
12. A downhole telemetry tool as claimed in claim 11 further comprising a pulser assembly having a flexible pressure compensation device in fluid communication on one side with the drilling fluid and on an opposite side with lubricating fluid inside the pulser assembly, and wherein the pressure transducer is inside the pulser assembly and configured to measure the drilling fluid pressure by measuring a pressure of the lubricating fluid.
13. A downhole telemetry tool as claimed in claim 10 wherein the memory further comprises program code executable by the processor to: encode the at least one selected frequency in a header message and transmit the header message to surface using the pressure pulse generator.
14. A downhole telemetry tool as claimed in claim 10 wherein the memory further comprises program code executable by the processor to: encode telemetry data into a pressure pulse telemetry signal and transmit the pressure pulse telemetry signal to surface at the at least one selected frequency using the pressure pulse generator.
15. A downhole telemetry tool as claimed in claim 10 further comprising at least one measurement-while-drilling (MWD) sensor communicative with the controller such that the controller can determine drilling conditions from data read from the at least one MWD sensor, and wherein the memory further comprises program code executable by the processor to: select a time period to emit the frequency sweep wave based at least in part on the determined drilling conditions.
16. A downhole telemetry tool as claimed in claim 15 wherein the memory further comprises program code executable by the processor to: emit the frequency sweep wave during a drill string idle time or when the drilling fluid is flowing but the telemetry tool is not transmitting any telemetry signals.
17. A downhole telemetry tool as claimed in claim 10 wherein the frequency sweep wave comprises a range of frequencies between 1 Hz and a maximum operating frequency of the telemetry tool.
18. A downhole telemetry tool in claim 10 wherein the step of determining the signal strength at each frequency in the range of frequencies comprises applying a time-frequency analysis to the measured pressure of the drilling fluid.
19. A downhole telemetry tool as claimed in claim 18 wherein the time-frequency analysis is selected from a group consisting of: Fourier transforms, wavelet analysis, and fast orthogonal search.
20. A downhole telemetry tool as claimed in claim 10 wherein the step of determining the signal strength at each frequency in the range of frequencies comprises determining a noise component at each frequency in the range of frequencies and selecting at least one frequency having a signal-to-noise ratio that meets a minimum signal-to-noise ratio threshold.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
DETAILED DESCRIPTION OF EMBODIMENTS
[0023] Directional terms such as “uphole” and “downhole” are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any apparatus is to be positioned during use, or to be mounted in an assembly or relative to an environment.
Overview
[0024] The embodiments described herein generally relate to a downhole telemetry tool having a fluid pressure pulse generator comprising a rotor and stator valve mechanism, a pressure transducer, and a controller programmed to perform a transmission frequency selection operation to automatically select one or more frequencies for transmitting a pressure pulse telemetry signal from the telemetry tool to surface. The fluid pressure pulse generator may be used for mud pulse (“MP”) telemetry used in downhole drilling, wherein a drilling fluid (“mud”) is used to transmit telemetry pulses to surface. A motor rotates the rotor relative to the stator between a fully opened position where there is no restriction of mud flowing through the fluid pressure pulse generator (and thus no pulse is generated), and a maximum restricted flow position where there is a maximum restriction of mud flowing through the fluid pressure pulse generator (and thus a pressure pulse of maximum amplitude is generated). The pressure transducer measures the pressure of the drilling fluid at the fluid pressure pulse generator. The controller is communicative with the pressure transducer and motor, and comprises a processor and a memory having encoded thereon a transmission frequency selection program that is executable by the processor to cause the pulse generator to generate a frequency sweep wave comprising a defined pulse pattern across a range of frequencies, to read pressure measurements taken by the pressure transducer during emission of the frequency sweep wave, and to determine whether any frequency in the frequency sweep wave is sufficiently free of undesired background noise for a telemetry signal transmitted by the telemetry tool to be received and decoded at surface.
Downhole Telemetry Tool
[0025] Referring to
[0026] Referring to
[0027] The fluid pressure pulse generator 30 is located at the downhole end of the downhole telemetry tool 20. Mud pumped from the surface by pump 2 flows along annular channel 55 between the outer surface of the pulser assembly 26 and the inner surface of the drill collar 27. When the mud reaches the fluid pressure pulse generator 30 it flows along an annular channel 56 provided between the external surface of the stator 40 and the internal surface of the flow bypass sleeve 70. The rotor 60 can rotate between an open position where mud flows freely through the fluid pressure pulse generator 30 resulting in no pressure pulse and a restricted flow position where flow of mud is restricted to generate pressure pulse 6.
[0028] The motor subassembly 25 is filled with a lubricating liquid such as hydraulic oil or silicon oil and this lubricating liquid is fluidly separated from mud flowing along the annular channel 55 by an annular seal 54 which surrounds the driveshaft 24. The pressure compensation device 48 comprises a flexible membrane 51 in fluid communication with the lubrication liquid on one side and with mud on the other side via ports 50 in the pulser assembly housing 49; this allows the pressure compensation device 48 to maintain the pressure of the lubrication liquid at about the same pressure as the mud at the fluid pressure pulse generator 30.
[0029] A pressure transducer 34 is mounted in the feed through connector 29 such that the pressure transducer 34 can measure the pressure of the lubrication liquid. Because the pressure of the lubrication liquid corresponds to the pressure of the drilling mud at the pulse generator 30, the pressure transducer 34 can be used to measure the pressure pulses 6 generated by the pulse generator 30.
[0030] The electronics subassembly 28 includes the controller 12, as well as downhole sensors and other components required by the downhole telemetry tool 20 to determine direction and inclination information and to take measurements of drilling conditions, to encode this telemetry data using one or more known modulation techniques into a carrier wave, and to send motor control signals to the motor and gearbox subassembly 23 to rotate the driveshaft 24 and rotor 60 in a controlled pattern to generate pressure pulses 6 representing the carrier wave for transmission to surface. Also, as will be described in more detail below in reference to
[0031] The fluid pressure pulse generator 30 can comprise a rotor/stator combination of different designs. One particular embodiment of a rotor/stator combination is shown in
Fluid Pressure Pulse Generator
[0032] Referring now to
[0033] A plurality of radially extending projections 42 are spaced equidistant around the downhole end of the stator body 41. Each stator projection 42 is tapered and narrower at its proximal end attached to the stator body 41 than at its distal end. The stator projections 42 have a radial profile with an uphole end or face 46 and a downhole end or face 45, with two opposed side faces 47 extending therebetween. A section of the radial profile of each stator projection 42 is tapered towards the uphole end or face 46 such that the uphole end or face 46 is narrower than the downhole end or face 45. The stator projections 42 have a rounded uphole end 46 and most of the stator projection 42 tapers towards the rounded uphole end 46.
[0034] Mud flowing along the external surface of the stator body 41 contacts the uphole end or face 46 of the stator projections 42 and flows through stator flow channels 43 defined by the side faces 47 of adjacently positioned stator projections 42. The stator flow channels 43 are curved or rounded at their proximal end closest to the stator body 41. The stator projections 42 and thus the stator flow channels 43 defined therebetween may be any shape and dimensioned to direct flow of mud through the stator flow channels 43.
[0035] The rotor 60 comprises a generally cylindrical rotor body 69 with a central bore therethrough and a plurality of radially extending projections 62. As shown in
[0036] The radially extending rotor projections 62 are spaced equidistant around the downhole end of the rotor body 69 and are axially positioned downhole relative to the stator projections 42. The rotor projections 62 rotate in and out of fluid communication with the stator flow channels 43 to generate pressure pulse 6 as is described in more detail below. Each rotor projection 62 has a radial profile including an uphole end or face and a downhole end or face 65, with two opposed side faces 67 and an end face 92 extending between the uphole end or face and the downhole end or face 65. The rotor projections 62 taper from the end face 92 towards the rotor body 69 so that the rotor projections 62 are narrower at the point that joins the rotor body 69 than at the end face 92. Each side face 67 has a bevelled or chamfered uphole edge 68 which is angled inwards towards the uphole face such that an uphole section of the radial profile of each of the rotor projections 62 tapers in an uphole direction towards the uphole face.
[0037] In order to generate fluid pressure pulses 6 a controller (not shown) in the electronics subassembly 28 sends motor control signals to the motor and gearbox subassembly 23 to rotate the driveshaft 24 and rotor 60 in a controlled pattern.
Electronics Subassembly
[0038] Referring now to
[0039] The modulation program utilizes a modulation technique that uses principles of known digital modulation techniques. In this embodiment, the encoder program code utilizes a modulation technique known as asymmetric phase shift keying (APSK) that is a combination of amplitude shift keying and phase shift keying to encode the telemetry data into a dual pulse height telemetry signal. Alternatively, another modulation technique can be used that includes amplitude shift keying only, or amplitude shift keying along with another type of modulation such as frequency shift keying.
[0040] Referring now to
[0041] The pulse generator 30 can be operated to transmit pulses at different frequencies by operating the rotor at different speeds. As the amount of undesired noise can vary between frequencies, the telemetry tool 20 can take advantage of its ability to transmit at different frequencies and its ability to measure the pressure profile of the mud medium at the telemetry tool 20 in order to select the best frequencies to transmit a telemetry signal, i.e. the frequencies with the least amount of undesired noise.
[0042] Referring to
[0043] In step 100, the transmission frequency selection program sends a control signal to the motor and gearbox subassembly to operate the pulse generator 30 to generate a frequency sweep wave 101 (as shown in
[0044] In step 102, the transmission frequency selection program reads the pressure transducer 34 during the period the frequency sweep wave 101 is being transmitted. An exemplary pressure reading 103 from the pressure transducer 34 is shown in
[0045] In step 104, the transmission frequency selection program analyzes the pressure reading 103 to determine a suitable transmission frequency. Multiple methods can be used to make this determination. In one embodiment, the pressure reading 103 is subtracted from the frequency sweep wave 101 to obtain a noise pattern 105 as shown in
[0046] Once the frequency or frequencies have been selected, the transmission frequency selection program at step 106 prepares a header message that includes the selected transmission frequency or frequencies, and instructs the controller 12 to encode this header message, and cause the pulse generator 30 to transmit a telemetry signal to surface containing this header message. This telemetry signal can be sent at the last transmitting frequency on the assumption that the surface receiver is configured to receive telemetry signals at this frequency, or at some other defined frequency which the surface frequency is configured to receive. Once the surface receiver receives this telemetry signal and decodes the header message, it will update its configuration to receive telemetry signals at the new frequency or frequencies. Optionally, the surface receiver can instruct a surface transmitter to transmit an acknowledgement message to the telemetry tool 20 which acknowledges that the frequency configuration has been updated.
[0047] In step 108, the transmission frequency selection program returns to step 100 to repeat the process of selecting a suitable transmission frequency, either immediately or after a certain period of time has elapsed. Optionally, the transmission frequency selection program can determine a suitable time to perform a transmission frequency selection operation based on the drilling conditions; the drilling conditions can be determined from measurements taken by the MWD sensors 18 and compared to defined criteria. For example, the MWD sensors 18 can determine when the mud density has changed; as mud density tends to affect the choice of telemetry signal frequency, the transmission frequency selection program can be executed whenever the mud density has changed beyond a defined threshold.
[0048] As the pressure transducer 34 is located upstream of the pulse generator 30, signal propagation from the pressure transducer 34 to surface behaves similarly to pressure wave propagations in an open pipe. Pressure wave reflections that travel from the pulse generator 30, down to the drill bit, and back up the pulse generator 30 can be captured with the pressure transducer 34 and accounted for when isolating the noise from the frequency sweep wave.
[0049] As the telemetry tool 20 can automatically select a suitable transmission frequency, an operator at surface does not need to manually select which transmitting frequency to use for each run/job. In addition to reducing the burden on the operator, the automatic transmission frequency selection by the telemetry tool 20 may also improve the telemetry transmission performance, as the telemetry tool 20 has the potential to react quickly to changing conditions. Further, the telemetry tool 20 that can automatically select the transmission frequency can potentially reduce the time required for an operator to set up the telemetry tool.
[0050] While particular embodiments have been described in this description, it is to be understood that other embodiments are possible and that the invention is not limited to the described embodiments and instead are defined by the claims.