AUTONOMOUS UNIT LAUNCHING SYSTEM FOR OIL AND GAS WELLS LOGGING, METHOD OF INSTALLATION AND UNINSTALLATION OF SAID AUTONOMOUS UNIT IN THE SYSTEM AND RESCUE SYSTEM

Abstract

A launching system for an autonomous unit (RAU) carrying a logging tool for oil and gas well logging robotic, said system comprising a main body provided with first and second control valves and a draining valve, sensors and a end cap electrically connected to a control room for transmission of the data collected by the logging tool carried by the RAU, said End Cap collecting data and charging the electrical battery of the robotic autonomous unit (RAU) carrying said logging tool to be launched by said main body and performing a schedule of logging tasks in the well; and a connection for a wellhead. The method for installation and uninstallation of the autonomous unit in the said system as well as a rescue system for the said robotic autonomous unit in case of hindered motion of the RAU for any reason are also described.

Claims

1. An autonomous unit launching system for oil and gas well logging, wherein said system comprises: a) a main body of generally cylindrical shape serving as a launching pipe for a robotic autonomous unit RAU carrying a logging tool, and where: (i) the upper portion of said main body is provided with a first control valve, or upper valve; (ii) the lower portion of same is provided with a second control valve or lower valve, both valves being for the controlled passage of the said logging tool carried by the said RAU; (iii) a third valve at the lower end of said body for the draining of fluids from the interior of said body, after the operation, before the uninstallation of said RAU; and, (iv) presence devices, selected among electromagnetic, optical, inductive or radio-frequency sensors, inserted internally or externally to the said launching system through said body to detect the presence of said autonomous tool at the surface, the change causing the sending of an electrical signal which triggers a sound or luminous warning; b) at the upper end of said body, an End Cap provided with attaching means to the said main body and electrically linked to a control central for transmission of data collected by the logging tool carried by said RAU, said End Cap (i) collecting data and charging the electrical battery of the autonomous unit RAU and (ii) effecting electronic communication with the said autonomous unit RAU carrying the logging tool designed for performing tasks in the well; and c) a connection for the wellhead, said connection being provided with attaching means at one end of same to the lower end of said main body and, at the other end of same, of attaching means to the wellhead to permit the installation of said system on the surface system.

2. The system in accordance with claim 1, wherein the End Cap is coupled to a data processing center.

3. The system in accordance with claim 1, wherein alternatively the End Cap is free from coupling to any data processing center.

4. The system in accordance with claim 1, wherein the main body is divided into various tubular sections interconnected to adjust the said body to the length suitable for the tool to operate in the well.

5. The system in accordance with claim 1, wherein the diameter of the main body 15 is variable.

6. The system in accordance with claim 1, wherein upon returning from the well task the autonomous unit RAU reduces the displacement speed and houses in the interior of said body, the displacement system of said autonomous unit being deactivated and an electrical connection being established between same and the said End Cap.

7. The system in accordance with claim 1, wherein said End Cap comprises: (i) an outer vessel for coupling with the upper end of said mast; (ii) a penetrator for electrical connection between said control central and the further components of said End Cap in sealed manner; (iii) a feeding and communication umbilical for data transmission to the RAU control and feeding central; (iv) an inductive transceptor for serial communication with the said autonomous unit; (v) a support for accommodating the induction coils to generate the electromagnetic fields for charging the battery of said autonomous unit; and (v) a control electronics for the management of the RAU battery charging and the communication between the RAU and the said control central.

8. The system in accordance with claim 1, wherein said system conveys data collected during the operation of the autonomous unit RAU in the well and stored in the RAU data module to devices external do said system.

9. A method for the installation and uninstallation of an autonomous unit RAU in the said launching system wherein said method comprises the following steps: a) Providing a launching system for autonomous unit for performing tasks in a well comprising a main body, an End Cap and a connection for connecting said main body and the well head; b) Coupling, with the aid of said connection, the said launching system to a wellhead; c) Installing said autonomous unit RAU in the interior of the main body of launching system, the said first, upper control valve being open and the second, lower control valve closed, the RAU being housed between said first and said second valves; d) Installing the End Cap at the upper end of main body of the said launching system; e) Opening the second, lower control valve of said main body and the flow control valve of the Christmas Tree to launch the RAU and enable the logging tool to start the well tasks; f) After the end of the well tasks, return the autonomous unit RAU to the surface, the reaching of the launching mast being signaled by a sound or visual warning; g) Closing the flow control valve of the Christmas Tree to hydraulically isolate said launching system from the well; h) Opening the said first, upper valve to enable the upper end of the RAU to be housed in the said End Cap; i) With the said upper end of the RAU housed in the said End Cap, recharging the RAU battery and collecting the obtained logging data, returning the RAU to the well if required; j) At the end of the process, opening the draining valve to flow the fluids which have penetrated said launching system during the operation; k) After the drainage of mast, closing the second, lower valve and disconnecting said system from the well head; and l) With the said system disconnected from the well head, withdrawing and disassembling the set system RAU.

10. A rescue system to replace the said End Cap, wherein said rescue system comprises: a) a Rescue End Cap (REC) with a sealed passage for a coated steel wire and flange for connection with the mast; b) a powered spool to unwind manually, locally or remotely said coated steel wire after the coupling of said REC to said mast; and c) coupled to said powered spool and coated steel wire, a rescue tool including a displacement system, the lower end of said tool being connected to a coupling and attachment system having the shape of a set of tweezers.

11. The rescue system according to claim 10, wherein after the rescue tool approaches the upper end of the RAU, a contact sensor is activated, sending a signal to the surface to inform the RAU location and the powered spool is activated to traction tweezers of the coupling and attachment system to start the withdrawal of the RAU from the well.

12. The rescue system according to claim 10, wherein, in use, in case of the impossibility of displacement of the RAU the following steps should be followed: a) Isolating the End Cap from the well and closing the flow control valve of the Christmas Tree or Wellhead and then withdraw End Cap from the mast; b) Inserting the rescue tool in the interior of mast and installing the ECR at the free upper end of said mast; c) Checking and verifying the installation and displacement of rescue tool; d) Opening the flow control valve of the Christmas Tree or Wellhead; e) Freeing the said coated steel wire by powered coil system to enable the lowering of tool through mast and the well until the upper end of the RAU is met; f) Consequent to said contact sensor activation, starting the RAU withdrawal with the aid of the powered spool after the complete closure of the set of tweezers around the RAU; g) Closing the flow control valve of the Christmas Tree or Wellhead after the rescue tool and the RAU enter the mast; h) Opening the draining valve for the withdrawal of fluids from the main body and i) Disconnecting mast of the well with ECR installed and with both the rescue tool and the RAU in the interior of said mast.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] FIG. 1 depicts a schematic drawing of the state-of-the-art wireline logging process.

[0057] FIG. 2 shows a schematic drawing of a wireline-lowered state-of-the-art logging tool coupled to a tractor to cover a high inclination well stretch.

[0058] FIG. 3 shows a front elevational view of a launching system or mast in accordance with the invention.

[0059] FIGS. 4A and 4B illustrate schematic drawings of the End Cap, positioned at the upper end of the mast to provide electronic access to the autonomous tool (RAU), data transmission and electric current feeding of the RAU battery.

[0060] FIG. 5 shows a perspective view of a rescue system to be used in case of hindrance or lack of movement of the robotic autonomous unit (RAU) in the well, the rescue system freeing the RAU and permitting its withdrawal.

DETAILED DESCRIPTION OF THE INVENTION

[0061] Throughout this specification and claims, the expressions autonomous unit or autonomous tool are equivalent and used indistinctively.

[0062] Further, during the present specification, the launching system which is the object of the invention is called launching mast or mast and therefore the expressions launching system and launching mast or mast should be considered as equivalent for the purposes of the invention.

[0063] The first aspect of the invention is the launching system of the autonomous unit designed to perform tasks in oil and gas wells, the system being generally designed by the numeral 100.

[0064] FIG. 1 attached shows a schematic drawing of wireline logging as practiced in the state-of-the-art technique. At the surface, a logging unit 1 comprises a central processing unit 2 including a data collecting, storing and analysis computerized system, as well as an electrical energy source for feeding a logging tool 6. The surface unit further comprises a wire traction system (winch) 3. At the well head (not represented) is installed a safety equipment designed by wire BOP 4, which can also include a lubricating system to allow the withdrawal of the logging cable 5 while the well is under flow. The logging wire 5 is in charge of the descent of the logging tool 6 throughout the well, the well wall 7 being either a casing or the contact area between the well and the rock itself crossed by the well, which features an open-well completion. The logging tool 6, which can use different working principles, measures specific properties of the rocks crossed by well 7 and of the zones of interest 8 carrying hydrocarbons and/or water.

[0065] FIG. 2 shows a further state of the art technique for the descent of logging tools into a well, in this case a high inclination well. Thus, a logging tool 6 is lowered by wire 5 coupled to a tractor 9 to cross a high inclination or horizontal well 10.

[0066] The present invention will now be described in relation with the attached Figures, which should not be construed as limiting same.

[0067] The launching system 100 of autonomous tools for tasks in oil and gas wells is illustrated in FIG. 3.

[0068] According to FIG. 3, the main body 15 is the main component of system 100, being made up of a tubular structure of circular section, preferably metallic but not limited to this kind of material. Body 15 can be subdivided in various tubular, interconnected sections to adjust the body 15 to the length suitable for the tool designed for operation in the well, the tubular structure or body 15 serving as housing and launching pipe for an autonomous unit RAU carrying a logging or wellbore working tool.

[0069] On the other hand, the diameter of body 15 is adapted for being compatible with a Christmas Tree or any other surface equipment.

[0070] Along the main body 15 are disposed components which make up the mast or system 100. The remaining components which constitute the system 100 will be described below in the present specification.

[0071] In the same FIG. 3 first, upper control valve 13 and second, lower control valve 14 positioned respectively at the upper portion and at the lower portion of body 15 are safety barriers which keep the tightness and safety of the well during execution of the autonomous tool (RAU) (not represented) tasks at the subsurface, said valves 13, 14 being (i) opened only for launching and withdrawing of the robotic autonomous unit; and (ii) flow control generic, safety valves, engaged either manually or remotely.

[0072] Control valves 13, 14 enable the controlled passage of the logging tool carried by the autonomous unit through the well head without the need to interrupt flow.

[0073] The respectively first and second control valves 13, 14 are connected to body 15 by flanges, threads or any other type of mechanical connection.

[0074] Presence sensing devices 16 are optical, inductive or radio frequency principle sensors. Sensors 16 are inserted internally or externally to mast 100 through main body 15. Devices 16 are generally positioned along main body 15 to be each positioned near control valves 13, 14.

[0075] Sensors 16 indicate the proximity of the autonomous unit (not represented) to the surface so that the autonomous unit arrival can be monitored at the end of the tasks for which it has been scheduled. When this occurs, the autonomous tool RAU reduces its displacement speed from the well (not represented) and is housed in the interior of body 15 of mast or system 100. The displacement system of said autonomous tool or unit is then deactivated and an electrical connection is established between said autonomous unit and the finishing component of the upper portion of main body 15, said finishing component being End Cap 18.

[0076] Draining valve or lower drain 17 positioned at the lower end of main body 15 is designed to drain, before the uninstallation of the launching system 100, the residual fluids which could penetrate said main body 15 during the operation. Valve or drain 17 is connected externally to that main body 15 by means of a thread or flange or any other mechanical connection device (not represented).

[0077] End Cap 18 is provided with an electronic system for activation or shut down (not represented) of the autonomous unit, said system being automatic or manual, according to the operator need. Activation or shut down will be carried out externally to the system or launching mast 100. It is not necessary for the autonomous unit to be kept activated without need. The same applies to opening/closing valve operations for starting or finishing the scheduled task. Activation is performed remotely by means of dedicated electronics and the shutting down will be automatically done by sensors (for example, an inductive proximity sensor) installed in said autonomous unit.

[0078] FIGS. 4A and 4B detail the End Cap 18. A control center (not represented) provides the electrical connections with End Cap 18 for transmitting data collected by the logging tool carried by the RAU as well as the recharging of said RAU battery (not represented).

[0079] In FIG. 4A an inductive transceptor 23 provides serial communication with the autonomous unit with no need of electrical contact. Support 24 accommodates induction coils 25 and inductive transceptor 26 to secure the alignment for interface with the autonomous unit RAU. Induction coils 25 generate electromagnetic fields for charging the battery of autonomous unit(s) where electrical contact would be required. Control electronics 26 manages the autonomous unit RAU battery charging as well as the communication between said RAU and the said control center.

[0080] In FIG. 4B an external vessel 20 behaves as a mechanical structure for coupling the End Cap 18 and the upper end of mast 100. A penetrator 21 makes the electrical connection between said control center and the further End Cap 18 components in a sealed manner. The feeding and communication umbilical 22 promotes a connection with a control central (not represented) for data transmission and electrical feeding.

[0081] The method for installing the autonomous tool RAU in body 15 of mast 100 will be described below. As for the RAU, it should be clear to the experts that the RAU has not been represented in the Figures of the present specification and that it can be any device of the kind and of common use in the practice of the art, and therefore the RAU is not an object of the present application.

[0082] With the mast 100 installed in the wellhead and the upper valve 13 open, the RAU is inserted in the interior of the main body 15 of the said mast and then the End Cap 18 is attached to the upper end of same by means of a connection device. The RAU should include a transceptor (not represented) of an optical, magnetic or inductive nature. Beside each upper and lower valve 13, 14, are positioned transceptors which identify the positioning of the RAU relative to the body 15 of the mast 100. The autonomous unit is at first positioned and identified at the upper portion of said body 15. After the RAU approaches the sensor 16 which is close to lower valve 14, said valve is automatically opened enabling the RAU to leave the body 15 of the mast 100 and enter the well. After the RAU displacement and therefore its distancing from upper and lower valves 13, 14, these valves close automatically.

[0083] After performing tasks in the well, such as logging tasks, the RAU returns to the body 15 of the mast 100. In the return path, when the RAU approaches the lower valve 14, said valve opens automatically and after the RAU enters the body 15 of mast 100 valve 14 is closed. By the approach of the RAU of the upper valve 13, the RAU follows its schedule, being uninstalled or returning to the well to perform further tasks.

[0084] It is possible to convey data collected during the operation of the robot autonomous unit (RAU) in the well and stored in the RAU data module towards devices external to the launching system 100. This is done when the RAU is connected to End Cap 18, enabling data collection. Transmission is performed through conventional wire connectors, USB or serial, for instance, or with the aid of a Bluetooth device to a cell phone/tablet/computer or by wireless to a control central. A LED display (not represented) installed in End Cap 18 shows that data transmission is taking place between said End Cap 18 and the robot autonomous unit RAU positioned in the launching system 100.

[0085] With the RAU connected to the End Cap 18, the electronics for battery recharging is activated and checks the amount of charge stored in the RAU. Recharging decision making is automatic or manual. A LED display (not represented) installed in End Cap 18 indicates either the need for recharging, if the recharge is being executed or even if the charge is complete. Recharging will be carried out by induction so there is no need to open mast 100.

[0086] At the lower end of the main body 15 of mast 100, a mechanical adaptor or connector 19 promotes the connection of said body 15 with the wellhead (not represented). The wellhead is a Christmas tree, a Production Head, a Casing Head or Blow out Preventer (BOP). Connection 19 is a flange, a thread or any other kind of mechanical connection compatible with the wellhead.

[0087] According to the invention, a control central (not represented) positioned remotely to the well where the task, such as logging, is executed can communicate with several systems or launching masts 100 simultaneously with the aid of mesh networks (online or off-line), enabling wider reaching with less packs loss and at higher speed.

[0088] Through the control central and the communication with End Cap 18, an operator (not represented) positioned remotely to the well can check if the RAU is attached, confirm the charge of the RAU battery, recharge the batteries and further collect data stored or schedule tasks for the RAU.

[0089] The second aspect of the invention is the method of installation and uninstallation of the autonomous unit RAU (not represented) in the mast 100 to perform tasks, such as logging, in the well.

[0090] According to said second aspect, the preliminary step involves coupling the mast or launching system 100 to a wellhead.

[0091] The RAU is at first installed in the interior or the main body 15 with the upper control valve 13 open and the lower control valve 14 closed, the RAU being housed in the interior of the main body 15 between the two valves 13, 14. Following the RAU installation, with the required tools duly coupled (not represented) to the main body 15 of the mast 100, the End Cap 18 is connected and installed at the upper end of body 15 of said mast 100.

[0092] For the launching of the RAU, at first the flow control valveselected among a swab valve or otherof the Christmas tree or wellhead (not represented) is opened. After the RAU approaches the sensor 16 of lower valve 14 said valve is automatically opened enabling the RAU to enter the well and start the tasks, such as logging. When the RAU is at a distance from valves 13, 14, said valves are automatically closed, the swab valve or any other flow control valve of the Christmas tree or well head being kept opened during the whole operation of the RAU in the well.

[0093] Upon return of the autonomous unit RAU to the surface and approach to the lower valve 14, said valve is automatically opened and after the entry of the RAU in mast 100 the lower valve 14 is closed. By continuing its ascending path through the main body 15, and when the RAU approaches the upper valve 13, said valve is opened and after identifying the RAU in the upper location of mast 100 the RAU is positioned in the End Cap 18.

[0094] It should be noticed that the flow control valve, such as a swab valve or any other valve of the kind, is closed only if the RAU is no longer intended to return to the well, that is, if the operation is concluded.

[0095] Housed in the End Cap 18, the battery of the autonomous unit RAU can be recharged, have data collected and return to the well if required following the same steps described above in the present specification. In case the well tasks are concluded, the swab valve or any other flow control valve of the Christmas Tree is closed and both the lower valve 14 and the drain or draining valve 17 are opened to let flow the fluids which could have penetrated the mast 100 during the operation. The system 100 can then be disconnected from the wellhead.

[0096] The description above confirms that contrary to other documents such as U.S. Pat. No. 9,528,348 B2 and other patent documents cited above in the present specification, the purpose of the present invention is a launching system for robot autonomous units (RAU) without need of wireline, coiled tubing or drilling or completion pipes. The system and method of the invention therefore enable any logging operation with the well in flow.

[0097] The third aspect of the invention is the utilization of a rescue system 30 provided with a Rescue End Cap (REC) 32 designed to replace End Cap 18 whenever it is impossible to move the RAU, the withdrawal of the RAU being required when it gets stuck consequent to any RAU damage or well obstruction.

[0098] Rescue system 30 is illustrated in FIG. 5.

[0099] It should be clear for the experts that although the RAU is not represented in any Figure, the upper end 27 of it is schematically represented in FIG. 5 to make the connection between said end 27 and rescue tool 29 clear.

[0100] In rescue system 30 the main component is Rescue End Cap (REC) 32, a sealed structure for passage of coated steel wire 33 and flange 34 for attachment to mast 100.

[0101] Rescue system 30 comprises a powered spool 31 to unwind manually, locally or remotely said coated steel wire 33, said steel wire being coupled to a rescue tool 29. The powered spool 31 is attached to REC 32 and actuated manually, locally or remotely after the attachment of REC 32 to mast 100. Rescue tool 29 is provided with a wheel and/or belt displacement system and at the end of said rescue tool 29 is attached a coupling and attachment mechanism 28 provided with a set of tweezers 28a to surround and grab the stuck RAU. When rescue tool 29 approaches the upper end 27 of the RAU, a contact sensor (not represented) will be activated and convey a signal to the surface to inform that the RAU has been detected. Then the powered spool 31 will be activated to traction tweezers 28a of the coupling and attachment mechanism 28 and start the withdrawal of the RAU from the well.

[0102] After the impossibility of moving the RAU is detected, the End Cap 18 should be isolated from the well by closing the safety valves 13, 14 and immediately withdrawn from mast 100.

[0103] It should be noted that during the RAU operation the End Cap 18 is permanently coupled to main body 15. However, after the logging task, or in case of the RAU imprisonment, the End Cap 18 is disconnected from said main body 15.

[0104] With the safety valves 13, 14 opened and the swab valve or any other flow control valve of the Christmas tree (not represented) closed, the rescue tool 29 is inserted in the interior of mast 100 and then ECR 30 is installed and attached to the upper free end of mast 100. After checking the installation and displacement of the rescue tool 29 the swab valve or any other flow control valve of the Christmas Tree (not represented) is opened and the powered spool 31 frees the coated steel wire 33 to enable the rescue tool 29 to be lowered actively through the mast 100 and then through the well until the upper end 27 of the RAU is found and contacted.

[0105] The contact sensor (not represented) is activated by the proximity of the rescue tool 29 with the upper end 27 of the RAU conveying to the surface the information that the RAU withdrawal can be triggered.

[0106] Following the complete closure of tweezers 28a of the coupling and attachment mechanism 28 around the RAU the displacement of the rescue tool 29 becomes passive and the powered spool 31 starts the rescue of the RAU (not represented).

[0107] After the rescue tool 29 and the captured RAU enter the mast 100, the swab valve or any other flow control valve of the Christmas tree (not represented) is closed, isolating the mast 100 from the well.

[0108] The mast 100 should be freed from the well with the rescue system 30 installed and the rescue tool 29 and the RAU in the interior of said rescue system 30.