Coiled Tubing Applications and Measurement Tool

Abstract

An apparatus and system for generating pressure pulses and gathering down-hole sensory information for enhancing and completing a well bore within a coiled tubing operation including: a valve longitudinally and axially positioned within the center of a pulser section and electronics to transmit and record down-hole sensory information. The main fluid flow is interrupted by the main valve which is operated by the controlled pilot fluid stream. The main fluid flow proceeds toward one or more pressure sensors to measure the fluid flow pressure with sensors that send signals to a Digital Signal Processor (DSP) that controls a valve which generates controllable and measurable energy pulses. Recorded downhole sensory information such as temperature, fluid bore and annulus pressure, weight/axial force, torque, vibration, shock, gravity tool-face, casing collar locator, gamma, flow and battery condition can be transmitted in real-time via pressure pulses to the surface with pulser or downloaded for analysis.

Claims

1. An apparatus that generates pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said apparatus comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows downward along said well bore said drilling fluid splits into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream flows through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then flows into a main valve fluid feed channel until it reaches said main valve pressure chamber and through a pilot valve section that functions as a pulser generating portion of said tool that further comprises a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can rotate said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid flows into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow to become a main exit fluid flow.

2. The tool of claim 1, wherein said upper and lower rotary seals exist within an oil filled pressure chamber and act to separate a portion of said pilot fluid stream fluid above or in front of said upper rotary seal from a portion exposed to atmospheric pressure that exists below or behind said lower rotary seal so that a drive shaft, a motor, and additional sections below said upper and lower rotary seals prevent pilot fluid stream fluid from entering and damaging said motor and associated electronics.

3. The tool of claim 1, wherein said pilot shaft is rotated by an electrical motor which is connected to said drive shaft and wherein said pilot inlet cam and said pilot outlet cam are positioned on said shaft so that both cams can rotate and so that when said pilot inlet cam is in an open position it allows said pilot fluid stream fluid to enter said main valve and simultaneously said pilot outlet cam maintains a closed position that prevents said pilot fluid stream fluid to exit through a reverse flow check valve.

4. The reverse flow check valve of claim 3, wherein said reverse flow check valve allows reverse fluid flow through said tool.

5. The reverse check valve and reverse fluid flow of claim 4, wherein resultant reverse fluid flow is does not cause pulsing of fluid while operation of a normal pulsing mode exists during a forward flow condition.

6. The tool of claim 1, wherein a frequency of opening and closing of a pilot inlet cam and a pilot outlet cam directly influences and determines one or more frequencies of said main valve opening and closing to create pressure pulses in a main fluid column above or in front of said main valve orifice.

7. The pilot flow check valve of claim 3, wherein upon a controlled signal said motor rotates said pilot shaft to position said pilot inlet cam to open and closed positions and wherein when said pilot inlet cam is a closed position said pilot outlet cam is in an open position said pilot fluid stream fluid behind or below said main valve to allowed escape through said reverse flow check valve and to join said main fluid flow.

8. The pilot flow check valve of claim 7, wherein said reverse flow check valve allows pilot fluid stream fluid to exit said main valve so that said pilot fluid stream fluid can return to a rear or lower position with respect to said main valve orifice.

9. The reverse flow check valve and reverse fluid flow of claim 5, wherein said check valve prevents fluid flow back into said tool by not allowing fluid to enter said pilot flow outlet channel which ensures blockage of fluid flow in a reverse direction through said tool and also allows closure of said main valve, thereby stopping further fluid flow.

10. The tool of claim 1, wherein a coupling mechanism toward a motor housing and wherein one or more annular pressure sensors measuring a pressure of flowing fluid is located inside a sensor sub assembly with sensors that send signals to a Digital Signal Processor (DSP) that controls tools and multiple sensors in real time while continuing to generate controllable, large, measurable, rapid energy pulses, improvement of weight on bit and an ability to time drill plugs allows for generation of small cuttings that are easily removed from downhole and also adjustment of pulse amplitude at any time without removing said tool from any coiled tubing downhole completion and/or drilling applications.

11. A system that generates pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said system comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows downward along said well bore said drilling fluid splits into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream flows through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then flows into a main valve fluid feed channel until it reaches said main valve pressure chamber and through a pilot valve section that functions as a pulser generating portion of said tool that further comprises a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can rotate said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid flows into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow to become a main exit fluid flow.

12. A method for generating pressure pulses in a drilling fluid within a well bore that exists within a coiled tubing assembly, said method comprising: a tool within which exists a valve portion longitudinally and axially positioned within a center portion of a main valve assembly, said assembly including a main valve, a main valve pressure chamber, and a main valve orifice with said main valve, such that as said drilling fluid flows is flowing downward along said well bore said drilling fluid splitting into both an inlet main fluid stream and a pilot fluid stream, wherein said pilot fluid stream is flowing through a pilot flow annulus and into a pilot flow inlet channel, wherein said pilot fluid stream then continues to flow into a main valve fluid feed channel until it reaches said main valve pressure chamber and continues through a pilot valve section that functions as a pulser generating portion of said tool further comprising a pilot valve housing, a pilot shaft positioned in a central axial position within said tool supported by thrust bearings, a seal carrier, upper and lower rotary seals, and a pilot inlet cam and a pilot outlet cam such that said pilot shaft can be rotating said pilot inlet cam and pilot outlet cam inside a pilot sleeve with matching orifices so that said pilot fluid stream is being controlled by movement of said pilot inlet cam and said pilot outlet cam and wherein said pilot fluid stream fluid continues flowing into and through a pilot flow outlet channel such that said pilot fluid stream fluid recombines with a main fluid flow for becoming a main exit fluid flow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] FIG. 1 provides a cross-sectional view of the Tool.

[0065] FIG. 2 is an enlarged cross-sectional view of the main valve section.

[0066] FIG. 3A is an enlarged cross-sectional view of the pilot valve section in relation to the main valve section.

[0067] FIG. 3B is a more complete cross-sectional view of the pilot valve section.

[0068] FIG. 4A is a cross-sectional view of the electronics located within the electronics section.

[0069] FIG. 4B is a cross-sectional view of the sensor subs located within the electronics section

[0070] FIG. 5 is an illustrated view of the power section of the Tool.

[0071] FIG. 6 provides graphical data from a CT field well intervention simulation.

[0072] FIG. 6A provides actual data on a CT operation with the Tool.

[0073] FIG. 7 provides a representation of change in pulse amplitude to dynamically change force on an end of a coiled tubing string.

DETAILED DESCRIPTION OF DRAWINGS

[0074] The present invention will now be described in greater detail and with reference to the accompanying drawings.

[0075] FIG. 1 shows the complete modular down-hole Tool [100] in its entirety. The Tool [100] has three major sections: the Pulser Section [101] that houses the main valve section [122] and pilot valve section [126], the electronics section [128] including the motor [130] and sensors described herein, and the power unit or the battery section [142] including the battery [502] as shown in FIG. 5.

[0076] The fluid enters the tool at the top where the tool is connected to the coil tubing by the Upper

[0077] String connection [132] also referred to in the industry as a top crossover connection. Respectively the fluid exits the tool at the bottom through the Lower String connection [150], also referred to in the industry as a bottom crossover connection, where the Tool [100] is connected to the downhole motor or other Bottom Hole Assembly (BHA) (not shown). The fluid flows through the tool on the inside of the Upper Pipe Portion [120] and Lower Pipe Portion

[0078] in the opening around the Motor [130], electronics [404], and battery [502] including the battery switch [601], as shown in FIG. 5.

[0079] FIG. 2 shows the main valve section [122] of the pulser section [101]. The fluid enters the tool through the Upper String connection [132] into the Fluid Inlet Cone [202] and also through the Pilot Flow Take Off ports [214] into the Pilot Flow upper Annulus [260] to the Pilot Flow Inlet Channel [320], bypassing the Main Valve Orifice [204]. The Pilot Flow upper Annulus [260] is created by the concentric Pulser Pipe [270] inside the Upper Pipe Portion [120] connecting the Fluid Inlet Cone [202] with the Main Valve Housing [210]. Radial apertures [211] are located along the circumferential area of the Flow Inlet Cone [202]. The main fluid flow in the center of the tool goes through the Main Valve Orifice [204] and around the Main Valve [206] in the open position, continuing around the internal parts of the entire Tool [100] until it exits through the Lower String Connection [150].

[0080] The Main Valve [206] in the closed position moves upward, or forward, into the Main Valve Orifice [204] restricting the main fluid flow and thus creating a backpressure in the fluid column upstream of the Main Valve Orifice [204]. The forward closing movement of the Main Valve [206] is activated by the pilot fluid which enters the Main Valve Housing [210] through the Pilot Flow Inlet Channel [320]. The Pilot Inlet Cam [316] in the open position allows the pilot fluid to enter the rear part of the Main Valve [206] and the higher pressure of the pilot fluid causes the Main Valve [206] to move forward against the Main Valve Orifice [204] which is smaller in diameter with less pressure across it. The Main Valve Plunger [208] provides a complete seal for the pilot fluid to allow full pressure to act on the Main Valve [206]. When the Pilot Inlet Cam [316] closes off the incoming pilot fluid to the rear of the Main Valve [206], the main fluid flow through the Main Valve Orifice [204] assisted by the Valve Spring [207] returns the Main Valve [206] to its rear, open position allowing the main fluid to flow through the tool.

[0081] FIG. 3A shows the Pulser Section [101 including the Main Valve Section [122] and the Pilot Valve Section [126] in relation to each other with their major internal components. The main fluid flow enters the Tool at the top into the Fluid Inlet Cone [202] and flows around the Main Valve [206] and around the Pilot Valve Housing [302].

[0082] FIG. 3B shows the Pilot Valve Section [126] of the Pulser Section [101]. The main fluid flows around the Pilot Valve Housing [302] inside the Upper Pipe Portion [120]. The Pilot Valve Section [126] consists of the Pilot Valve Housing [302], the Pilot Shaft [304] which is positioned centrally and axially located and supported by Thrust Bearings [306], a Seal Carrier [308], Upper and Lower Rotary Seals [310, 311], and Pilot Inlet Cam [316] and Pilot Outlet Cam [314]. The Pilot Shaft [304] rotates the Pilot Inlet Cam [216] and the Pilot Outlet Cam [314] inside the Pilot Sleeve [318] which has matching holes to allow the pilot fluid flow to be controlled by the cams. The Upper and Lower Rotary Seals [310, 311] in the Oil Filled Chamber [326] separate the pilot fluid side above or in front of the upper Rotary Seal [310] from the air side below the lower Rotary Seal [311] housing the Drive Shaft [305], Motor [130] and below, thus preventing the pilot fluid from entering and damaging the Motor [130] and the Electronics [404]. The Pilot Shaft [304] is rotated by the electric Motor [130] which is connected to it with a Drive Shaft [305]. The Pilot Inlet Cam [316] and the Pilot Outlet Cam [314] are positioned on the shaft rotationally so that when the Pilot Inlet Cam [316] is in open position it allows pilot fluid to enter the Main Valve [206]. At the same time the Pilot Outlet Cam [314] is in closed position preventing the fluid to exit through the Reverse Flow Check Valve [325]. Upon a controlled signal the Motor [130] rotates the Pilot Shaft [304] to position the Pilot Inlet Cam [316] to open and closed positions. When the Pilot Inlet Cam [316] is in closed position, the Pilot Outlet Cam [314] is in open position allowing the pilot fluid behind the Main Valve [206] to escape through the Reverse Flow Check Valve [325] to join the main fluid flow. The Reverse Flow Check Valve [325] allows the pilot fluid to exit the Main Valve [206] thus allowing it to return to the rear position away from the Main Valve Orifice [204]. Without the Reverse Flow Check Valve [325] in the case when the fluid may flow backward in the tool, the incoming fluid coming up from the lower part of the tool would enter the Pilot Flow Outlet Channel [322], which is an opening closed by a check valve, and would push the Main Valve [206] forward into the Main Valve Orifice [204] and thus blocking the fluid flow in the reverse direction through the tool. To prevent such case, the Reverse Flow Check Valve [325] prevents the fluid flow coming up the tool from below from entering the Pilot Flow Outlet Channel [322] to cause the Main Valve [206] to close to stop the fluid flow. With the Reverse Flow Check Valve [325] in place the tool can allow reverse fluid flow through the tool, although not pulsing the fluid, but still operating in normal pulsing mode in forward flow condition. The frequency of opening and closing the Pilot Inlet and Pilot Outlet Cams [316, 314] determines the frequency of the Main Valve [206] closing and opening and creating pressure pulses in the main fluid column in front of the Main Valve Orifice [204].

[0083] FIG. 4A shows the Electronics Section [128] of the tool located in the Pressure Housing [408] inside the upper pipe portion [120], is downstream of the Pulser Section [101] and before the Power unit or the battery Section [142]. The Electronics [404] control the Motor [130] and Pilot Shaft [304] rotation which drives the Main Valve [206] to create positive pressure pulses in the main fluid. The Electronics [404] not only control the Motor [130] but also collect continuous data from all sensors on board and auxiliary, and monitors power. Sensors may include temperature, fluid bore and annulus pressure, weight/axial force, torque, vibration, shock, gravity tool-face, casing collar locator, gamma, flow and others.

[0084] FIG. 4B shows the Pressure Sensor Sub [411] and Weight Sensor Sub [415] of the Electronics Section [128]. The Pressure Sensor Sub [411] is directly connected to the Upper Pipe Portion [120] and also to the Electronics [404] inside the center of the concentric Pressure Housing [408]. The Weight Sensor Sub [415] is directly connected to the Pressure Sensor Sub [411] and the Lower Pipe Portion [140] below. The main fluid between the Upper Pipe Portion [120] and the Pressure Housing [408] continues into the Flow Through Channels [410] through the Pressure Sensor Sub [411] and the Weight Sensor Sub [415]. The Pressure Sensor Sub [411] houses the Bore Pressure Sensor [409] measuring the main fluid pressure inside the Tool [100] in front of the Pressure Sensor Sub [411]. The Annulus Pressure Sensor [413] measures the fluid pressure in the annulus, on the outside of the Upper Pipe Portion [120]. The Communication Port [412] is accessible from the outside of the Tool [100] and it is sealed to the fluid and pressure in the annulus (not shown). The Communication Port [412] allows programing of the Tool and downloading of memory data when the Tool [100] is assembled. The Pressure Sensor Sub [411] may also contain another Bore Pressure Sensor [409] downstream of the Flow Through Channels [410] to measure fluid flow.

[0085] The Weight Sensor Sub [415] houses the Weight and Torque Sensors [414] measure axial force and torque on the Tool [100]. The measurement of the torque is essential to monitor the performance of the down-hole motor [130] and its operation. The torque on the sub is created by the Lower Pipe Portion [140] below the Weight Sensor Sub [415] and the Upper Pipe Portion [120] above the Pressure Sensor Sub [411]. Wiring from the Power unit or the battery Section [142] below and the wiring of the Weight Sensor Sub [415] run through the Pressure Sensor Sub [411] to the Electronics [404]. The main fluid flow goes through the Weight Sensor Sub [415] similar to the Pressure Sensor Sub [411], in the Flow Through Channels [410] between the outside wall of the Weight Sensor Sub [415] and the center concentric opening where the Weight and Torque Sensors [414] are located.

[0086] FIG. 5 shows the lower end of the Power Unit or the Battery Section [142] of the Tool [100] which houses the Battery [502] and the Battery Switch [601]. The main fluid coming from the Weight Sensor Sub [415] above the Battery [502] flows between the Lower Pipe Portion [140] and the Battery Pressure Housing [603]. The fluid converges passed the Battery Switch Centralizer [608] to the center flow area of the Lower String Connection [150] where it exits the Tool [100] to the down-hole motor or BHA (not shown). The Battery Switch [601] holds the Battery [502] in the Battery Pressure Housing [603] and seals the Battery [502] from the main fluid. The Battery [502] is pressed against the Battery Switch Plunger [604] by the Battery Spring [503]. The Battery Switch Screw [606] allows a limited rotation in and out which moves the Battery Switch plunger [604]. This allows the Battery [502] to move to or away from the connection to the Weight Sensor Sub [415], thus connecting or disconnecting power to the Electronics Section [128]. When the Battery Switch Screw [606] is rotated in the forward position, the Battery Switch Plunger [604] pushes the Battery [502] forward to engage with the connector in the Weight Sensor Sub [415] and thereby powering the Tool [100] and the Electronics [404]. The Battery Switch [601] also has a safety feature built in by the Battery Switch Safety Lock [607]. When the Battery Switch Screw [606] is screwed in and the Battery [502] is engaged and powering the Electronics [404], the spring loaded Battery Switch Safety Lock [607] are pushed by springs in the way of the Battery Switch Screw [606] preventing it from accidentally unscrewing and allowing the Battery [502] to disengage during Tool [100] operation. A supplied special tool inserted through the center of the Battery Switch Centralizer [608] is required to push the Battery Switch Safety Lock [607] out of the way so the Battery Switch Screw [606] can be unscrewed to disengage the Battery [502]. When the Tool [100] is in operation, the Battery Switch Centralizer [608] prevents the Battery Pressure Housing [603] from radial vibration and holds the Tool [100] in compression in the axial direction from the Lower String Connection [150].

WORKING EXAMPLE 1

[0087] Location: West Texas, USA

[0088] Application: Coil-frac

[0089] Well Depth (TVD): 11,000 ft. (3,350 m)

[0090] Lateral Length: 8,000 ft. (2,450 m)

[0091] Sliding Sleeves: 80

[0092] FIG. 6 provides data on a well intervention simulation for CT. Pre-job modeling shows that RIH surface weight would not be sufficient to convey the coil to TD, indicating the need for an extended-reach tool. FIG. 6A provides actual data on a CT operation with the Tool [100] of the present disclosure.

[0093] Results of the Tool [100] CT operation show that the TD was successfully reached without assistance from frac pumps tied into the annulus. A pound force measurement of 20,000 lbf (1 lbf=4.448222 N) on surface weight was maintained, indicating the transfer of weight to BHA (as graphically shown in [680]), advancing across 80 sleeves to TD, as graphically shown in [690]. The operator concluded that an even deeper reach could have been achieved with the Tool.

WORKING EXAMPLE 2

[0094] Location: North Dakota, USA

[0095] Application: Coil tubing

[0096] Well Depth (TVD): 11,000 ft. (3,350 m)

[0097] Lateral Length: 8,000 ft. (2,450 m)

[0098] Sliding Sleeves: 80

[0099] The Tool [100] provides a water hammer-style ER tool with a known and adjustable force setting which optimizes the lateral reach of the CT and more closely matches pre-run simulation models. The data telemetry of the Tool [100] system reduced risk and the thruster provides consistent axial pull for deeper, faster coiled tubing runs. Obtaining real-time downhole pulse amplitude data during extended reach operations is provided in FIG. 7. The Tool [100] system allows the operator to know exactly what size force the tool will generate. The water hammer pulses of 1,000 psi generate an average of 4,000 lbf pull on the end of the CT string at BHA.