Downhole sensor system using resonant source
10669817 ยท 2020-06-02
Assignee
Inventors
Cpc classification
E21B47/12
FIXED CONSTRUCTIONS
International classification
E21B41/00
FIXED CONSTRUCTIONS
E21B47/01
FIXED CONSTRUCTIONS
E21B47/12
FIXED CONSTRUCTIONS
Abstract
A well telemetry system supplies power to downhole sensor nodes employed for obtaining telemetry data in oil wells. The nodes are held in the cement that lines the well and surround the casing. At the surface, an AC power unit is connected to the casing and geological structure that surrounds the cement. Power to nodes is supplied using an AC resonant circuit that generates standing waves of electrical power on the casing. Power from the standing waves is delivered to the nodes which are located at antinodes of the standing wave. The nodes are held in cement that surround the casing, with one of their two electrodes connected to the casing and the other connected to the cement or to geological structure.
Claims
1. A downhole node for a well, comprising: a node housing set in cement, the cement surrounding a casing of the well, a power electrode extending from the node housing to the casing; and a ground electrode extending from the node housing to the cement and/or surrounding geologic structure; wherein the node is powered by a power source for transmitting AC power to the node via the casing by establishing a standing wave in the casing, wherein the power source adjusts a frequency of the AC power to ensure that the node is located at an antinode of the standing wave.
2. The node of claim 1, wherein the node comprises node circuitry including a tuned filter for receiving power via the power electrode and being grounded via the ground electrode.
3. The node of claim 1, wherein the node comprises node circuitry including a bridge circuit for rectifying power transmitted via the casing.
4. The node of claim 1, wherein the node comprises node circuitry including a regulated supply for conditioning power transmitted via the casing.
5. The node of claim 1, wherein the node comprises node circuitry including a Zener diode connected between the power electrode and ground electrode for protecting the node from over voltage.
6. The node of claim 1, further comprising an insulating cover over the casing.
7. The node of claim 6, wherein the insulating cover is a layer of plastic.
8. The node of claim 6, wherein the insulating cover is a paint layer.
9. The node of claim 1, wherein the power electrode connection to the casing is protected with a glass-to-metal seal.
10. A well telemetry system for a well, comprising: one or more nodes set in cement, the cement surrounding a casing of the well; and a power source for transmitting AC power to the nodes via the casing by establishing a standing wave in the casing; and wherein the power source adjusts a frequency of the AC power to ensure that the nodes are located at antinodes of the standing wave.
11. The system of claim 10, wherein a frequency of the AC power from the power source is tuned in response to data from the nodes.
12. The system of claim 10, further comprising an insulating cover over the casing.
13. The system of claim 12, wherein the insulating cover is a layer of plastic.
14. The system of claim 12, wherein the insulating cover is a paint layer.
15. The system of claim 10, wherein each of the nodes comprises: a node housing set in the cement; a power electrode extending from the node housing to the casing; and a ground electrode extending from the node housing to the cement and/or surrounding geologic structure.
16. The system of claim 15, wherein the nodes each comprise node circuitry including a tuned filter for receiving power via the power electrode and being grounded via the ground electrode.
17. The system of claim 15, wherein the nodes each comprise node circuitry including a bridge circuit for rectifying the AC power transmitted via the casing.
18. The system of claim 15, wherein the node comprises node circuitry including a regulated supply for conditioning the power transmitted via the casing.
19. The system of claim 15, further comprising an insulating cover over the casing.
20. The system of claim 19, wherein the insulating cover is a layer of plastic or a paint layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(16) The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
(17) As used herein, the term and/or includes any and all combinations of one or more of the associated listed items. Further, the singular forms and the articles a, an and the are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms: includes, comprises, including and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Further, it will be understood that when an element, including component or subsystem, is referred to and/or shown as being connected or coupled to another element, it can be directly connected or coupled to the other element or intervening elements may be present.
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(19) The casing 20 in the figure is shown as three steel pipes or casing sections 25-1, 25-2 and 25-3, counting from top. They are joined at two couplings 25-1-2 and 25-2-3. The first coupling 25-1-2 joins the first two pipes 25-1 and 25-2, the second coupling 25-2-3 joins the 2.sup.nd and 3.sup.rd pipes 25-2 and 25-3; and so on. At the couplings, there may or may not be DC connectivity, but the couplings act as capacitors which does allow AC current transmission.
(20) As shown in the diagram, the gap between the hole in the geologic structure 50 and the casing is filled with cement 55. The cement 55 cylindrically lines the wall of the well and surrounds the well casing 20. Since the nodes are typically located just below the couplings, 25-1-2 and 25-2-3 will also denote node locations; i.e., location of nodes. The nodes 60-1 and 60-2 are encased in cement and attached to the casing just below couplings 25-1-2 and 25-2-3, in the illustrated example. The node ground terminal portions 70 and 75 are described later in connection with
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(26) An alternate embodiment of the AC power unit connection is possible where instead of cement the geologic structure can be used to complete the AC circuit. Thus, the AC unit supplies power to nodes using the casing and the geologic structure. This requires an alternate configuration of AC unit's ground connection 10 as shown in
(27) It may be preferable to use cement 55 instead of geologic structure 50 for power delivery and completing the circuit of the AC unit. First, cement is (or can be made by adding dopants) more electrically conductive than the geologic structure. Second, it may be easier to secure the electrode portions 75 and 70 inside cement than to push the insulated portion 70 though cement and expose portion 75 in the geologic structure.
(28) Yet another alternate embodiment of
(29) The present approach uses circuitry modeling with inputs of estimated electrical parameters to determine starting values for AC power supply specifications and settings. These parameters, such as impedance, resistivity, capacitance, etc., are estimates from available data and/or electrically modeling of the underground rig's physical layout and its electrical properties. The system controller 700 fine tunes the power supply specifications, frequency and peak voltage settings, starting from the values obtained from circuitry modeling.
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(31) Regarding the results displayed in
(32) A few impulse impedance measurements have been published that characterize vertically-oriented conductive structures buried in soil, but not to depths representative of a downhole casing.
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(36) The next figure,
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(38) It is important to note that for a well with different electrical parameters, these numbers will be different. These numbers are cited for illustrative purposes for a typical well with typical RLC values.
(39) Although the efficiency in power delivery to the deeply buried node is low, relatively low charging power can be sufficient for intermittent operation of (underground) low power node electronics. If more power is needed, the peak source voltage can be increased. Furthermore, a single source at the surface can power multiple nodes.
(40) The circuit embodied in
(41) In general, the nodes may be located at arbitrary positions along the casing. Electrical parameters, i.e., frequency and power, of the power delivery system can be tuned such that standing wave maxima coincide with the nodes whose telemetry signals are desired. It may not be necessary to monitor all the nodes simultaneously at all times. For example, as the well gets deeper, measurements from certain nodes closer to the surface may not be required. The power delivery system, therefore, can focus on delivering power to the deeper nodes. Similarly, power delivery can also be scheduled for different nodes at different times during daily operations of the well the day.
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(43) The power extraction circuit components, which act in sequence, are the tuned filter 505, bridge 510 and regulated supply 515.
(44) The input power to tuned filter 505 of power extraction circuit comes from the node's casing electrode 65, which is in direct contact with casing through electrode 15 of the AC power unit 1510. In examples, the connections to the casing are made using a glass-to-metal seal with an electrically isolated button.
(45) To complete the AC circuit, the node's second electrode 75 is connected to the AC power unit's (1510) ground stake 10 through the geologic structure 50 or cement 55 (
(46) The capacitors C1, C2 and C3 and the inductor L1 are configured to act as a low-pass filter to deny high frequency AC components to pass to the bridge circuit 510. Ground connection G2 allows any excess AC current to flow to the ground. The Zener diode 520 controls the voltage passed though the tuned filter 505. The diode 520 thus acts as surge protector.
(47) The bridge 510 in the middle of power extraction circuitry to converts AC output to DC voltage. The diodes D1, D2, D3 and D4 in the bridge circuit 510, which is a full wave rectifier, shunt DC component into the + line.
(48) The regulated supply circuitry 515 uses the inductor L2 to further filter out high frequency components and condition the voltage and current. The diode D5 and capacitor C4 ensure direct flow of DC current to the transducer 550 and also possibly the node control unit 600 and data transmission unit 67. Finally the regulator 590 acts to control the voltage level for the transducer 550.
(49) The transducer 550 requires DC voltage to power its electronics directly and/or to charge its battery that provides power to the node electronics. The output of the DC power from the power extraction circuit 64 is of fixed polarity indicated by + and signs.
(50) The node control unit 600, typically a microcontroller, regulates the tunable transformer T in tuned filter 505. The node control unit reads the transducer 550 and also the information from the transducer to the data transmission unit 67. The transmission unit encodes the transducer information as telemetry data, which is then transmitted to the TCU 100.
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(52) In general, the control system 700 tunes the AC power unit 1510 to operate at optimum frequency and power (peak voltage) so that all the nodes will have sufficient power to sense and transmit data to the telemetry control (TCU) 100.
(53) The frequency is the more difficult of the two parameters, voltage and frequency, to determine. The optimum frequency will create the standing waves in the casting 20. The frequency is selected so that the positions of maximum power (antinodes) will be approximately located at the locations of the various nodes 60-1, 60-2 along the casing. Determination of voltage is a simple matter of scaling the AC unit's power. It must be scaled to a value that will deliver needed the power to the farthest (deepest location) node 60. Even though the nodes will all be located at the relative maxima (antinodes) of the standing waves, those at the deepest parts of casing will get progressively less power. Therefore, in order to ensure that all nodes 60 have enough power, one must scale the AC power (peak voltage) to match the requirement of the node located at the highest depth.
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(55) More than likely the guesses of frequency and voltage values obtained from steps 725 and 730, which are based on simulations, will not be the ideal parameters for the real world power requirements at the nodes 60. Whether the power and voltage specifications of the power unit 1510 are adequate, i.e., the frequency and peak voltage produce a resonance LC circuit with enough power for the nodes, will be determined by the control unit 700 after receiving proper response from the TCU 100 in step 750. The TCE 100 responds based on the telemetry data transmitted by the various nodes 60-1, 60-2 along the casing 20.
(56) In step 760, the control unit decides, based on and YES or NO response from the TCU 100, if AC power specifications are correct or not. If the response is YES, this will signify that nodes are functioning properly and telemetry data acquisition can proceed as normal. On the other hand if the decision in step 760 is a NO, indicating inadequate power supply to the nodes, step 740 will be repeated with a new pair of incrementally changed frequency and voltage specifications. Thus, the tuning of the AC power unit is an iterative process, primarily based on the response from the TCU 100.
(57) Iterations of frequency and power in 740 depend on a YES or NO signal from TCU 100. If there is an absence of any signal (neither YES nor NO) from some or all of the nodes, it probably points to fully discharged batteries at the nodes and/or the fact that the nodes' electrode connections are located at a nodal point of the standing wave. Until the nodes are able to communicate with TCU 100, frequency and power parameters must be determined by a hunt and wait method, which can be automated using software. The hunt part describes selecting a power specification (frequency and peak voltage) to supply power to the nodes, and the wait part refers to waiting for the nodes to start communication with TCU 100. After a reasonable time, if the nodes are still not communicating one must try a different frequency and power for the AC unit.
(58) This method is necessary if the node batteries are completely exhausted and their electrical circuitry cannot be activated until the batteries are fully charged. Typically, in most devices such as cell phones and computers, active power supply will activate the electronic and charge the battery simultaneously. So there may not be a need to wait for the batteries to be charged.
(59) Having described the hunt and wait nature of the iterative tuning of AC power unit parameters, it should be noted that the simulation method described in this invention to determine initial parameters of the AC power unit should be good starting points of the parameter values, and they should make the hunt and wait method not an insurmountable problem.
(60) While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.