Systems, assemblies and processes for controlling tools in a well bore
10107071 ยท 2018-10-23
Assignee
Inventors
Cpc classification
E21B47/138
FIXED CONSTRUCTIONS
E21B47/13
FIXED CONSTRUCTIONS
E21B47/12
FIXED CONSTRUCTIONS
International classification
E21B34/10
FIXED CONSTRUCTIONS
Abstract
A dedicated hydraulic line for transmission of a signal device capable of generating one or more unique signals to one or more tools within a subterranean well. Each tool can be equipped with a reader device for receiving signals from and transmitting signals to the signal device. Each reader device can control operation of the tool associated therewith if the reader device is programmed to respond to signals received from the control device. Hydraulic fluid used to operate the tool can be conveyed via the dedicated hydraulic line or a separate hydraulic line. A separate hydraulic line can be used to reset the tool.
Claims
1. A hydraulic control system for use in a subterranean well comprising: at least one tool positioned along production casing within the subterranean well; a first hydraulic line positioned in the subterranean well outside of the production casing and connected to each of said at least one tool via separate hydraulic connections, said first hydraulic line sized to permit passage of both a signal device and hydraulic fluid therethrough; at least one first valve corresponding in number to said at least one tool, each of said at least one first valve being positioned in separate one of the hydraulic connections between said first hydraulic line and said at least one tool; and at least one reader device corresponding in number to said at least one first valve, each of said at least one reader device being connected to a separate one of said at least one first valve so as to control the actuation thereof.
2. The hydraulic control system of claim 1 wherein said first hydraulic line has one end at or near the surface of the earth.
3. The hydraulic control system of claim 2 wherein said first hydraulic line has another end that is open to the well.
4. The hydraulic control system of claim 3 further comprising: a second valve positioned in said first hydraulic line at a position more distal from the surface of the earth than any of said hydraulic connections; and a second reader device for controlling the actuation of said second valve.
5. The hydraulic control system of claim 1 wherein said signal device is capable of generating one or more unique signals.
6. The hydraulic control system of claim 5 wherein said signal device is a radio frequency identification device, a device carrying a magnetic bar code, a radioactive device, an acoustic device, a surface acoustic wave device, or a low frequency magnetic transmitter.
7. The hydraulic control system of claim 6 wherein said reader device is connected to a battery.
8. The hydraulic control system of claim 6 wherein said reader device has an antenna.
9. The hydraulic control system of claim 8 wherein said antenna substantially surrounds said first hydraulic line.
10. The hydraulic control system of claim 9 wherein said antenna is configured substantially as a coil and said first hydraulic line extends through said coil.
11. The hydraulic control system of claim 1 wherein said at least one tool is a plurality of tools.
12. The hydraulic control system of claim 1 wherein said first hydraulic line extends in an annulus between the production casing and intermediate casing within the subterranean well.
13. The hydraulic control system of claim 1 wherein said first hydraulic line has an inner diameter of from about 0.15 inch to about 0.40 inch.
14. The hydraulic control system of claim 1 wherein said signal device is sized and configured to inhibit said signal device from tumbling during passage in said first hydraulic line.
15. The hydraulic control system of claim 1 wherein said first hydraulic line is secured to said production casing.
16. The hydraulic control system of claim 1 further comprising: a second hydraulic line positioned in a subterranean well and hydraulically connected to each of said at least one tool such that increasing hydraulic pressure in said first hydraulic line moves a component in said tool one direction while increasing pressure in said second hydraulic line moves said component in an opposite direction.
17. The hydraulic control system of claim 16 wherein said first hydraulic line and said second hydraulic line are connected.
18. The hydraulic control system of claim 17 further comprising: a third valve substantially at the connection of said first hydraulic line and said second hydraulic line.
19. The hydraulic control system of claim 18 further comprising: a third reader device for controlling the actuation of said third valve.
20. The hydraulic control system of claim 16 wherein said second hydraulic line is positioned in the subterranean well outside of the production casing.
21. A process comprising: conveying at least one signal device capable of generating one or more unique signals from a well head through a first hydraulic line positioned in a subterranean well outside of production casing and extending adjacent each of at least one tool that is positioned along the production casing; conveying hydraulic fluid via said first hydraulic line that is positioned outside the production casing in a subterranean well and hydraulically connected to each of said at least one tool; and controlling flow of said hydraulic fluid to at least one of said at least one tool based upon said one or more unique signals.
22. The process of claim 21 further comprising: discharging said at least one signal device from the first hydraulic line into the well.
23. The process of claim 21 wherein said at least one signal device controls the operation of a plurality of tools.
24. The process of claim 21 wherein each of said at least one tool has a reader device connected thereto that is capable of receiving one or more unique signals from each of said at least one signal device and controlling the operation of the tool connected thereto by controlling flow of said hydraulic fluid upon receipt of specific unique signal that the reader device is programmed to respond to.
25. The process of claim 24 further comprising: transmitting a signal from said reader device to said at least one signal device.
26. The process of claim 21 wherein said at least one signal device is a radio frequency identification device, a device carrying a magnetic bar code, a radioactive device, an acoustic device, a surface acoustic wave device, or a low frequency magnetic transmitter.
27. The process of claim 21 wherein said at least one signal device is conveyed from the surface of the earth through said first hydraulic line.
28. The process of claim 21 further comprising: conveying hydraulic fluid to said at least one tool via a second hydraulic line positioned in the well so as to reset said tool after hydraulic fluid is conveyed via said first hydraulic line.
29. The process of claim 28 wherein said first hydraulic line is connected to said second hydraulic line in the well, the process further comprising: conveying said at least one signal device to the surface of the earth.
30. The process of claim 28 further comprising: transmitting a signal from said reader device to said at least one signal device.
31. The process of claim 30 further comprising: measuring well, formation, fluid conditions or combinations thereof by means of gauges that said at least one signal device is equipped with.
32. The process of claim 31 wherein said first hydraulic line is connected to said second hydraulic line in the well, the process further comprising: conveying said at least one signal device to the surface of the earth.
33. The process of claim 21 wherein said first hydraulic line extends in an annulus between the production casing and intermediate casing within the subterranean well.
34. The process of claim 21 wherein said first hydraulic line has an inner diameter of from about 0.15 inch to about 0.40 inch.
35. A process comprising: conveying hydraulic fluid from a well head via a first hydraulic line that is positioned in a subterranean well outside of production casing and extends adjacent at least one tool that is positioned in the well along the production casing; conveying at least one signal device through said first hydraulic line positioned in the subterranean well, each of said at least one signal device capable of generating one or more unique signals; and transmitting a control signal based upon receipt of said one or more unique signals by a reader device so as to control the flow of said hydraulic fluid from said first hydraulic line to said at least one tool to actuate the tool.
36. The process of claim 35 wherein each of said at least one tool has a separate reader device connected thereto capable of receiving said one or more unique signals.
37. The process of claim 36 further comprising: transmitting a signal from said reader device to said at least one signal device.
38. The process of claim 35 wherein said first hydraulic line is connected to a second hydraulic line in the well, the process further comprising: conveying said at least one signal device to the surface of the earth via said second hydraulic line.
39. The process of claim 35 further comprising: measuring well, formation, fluid conditions or combinations thereof by means of gauges that said at least one signal device is equipped with.
40. The process of claim 39 wherein said first hydraulic line is connected to a second hydraulic line in the well, the process further comprising: conveying said at least one signal device to the surface of the earth via said second hydraulic line.
41. The process of claim 35 further comprising: conveying hydraulic fluid to said at least one tool via a second hydraulic line positioned in the well so as to reset said tool after hydraulic fluid is conveyed via said first hydraulic line.
42. The process of claim 35 wherein said well has a substantially horizontal portion and said first hydraulic line extends into said substantially horizontal portion.
43. The process of claim 35 wherein said first hydraulic line extends in an annulus between the production casing and intermediate casing within the subterranean well.
44. The process of claim 35 wherein said first hydraulic line has an inner diameter of from about 0.15 inch to about 0.40 inch.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention.
(2) In the drawings:
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(13) As utilized throughout this description, the term signal control line refers to a continuous or jointed line, conduit, tubular or similar structure for conveying fluid and a signal device. The substantially axial bore through the control line is sufficient to permit passage of a signal device therethrough but the outside diameter of the control line is sufficiently small so as not to impede placement of other lines, tubulars, tools and equipment within the well. A nonlimiting example of suitable diameters for a signal control line are an outside diameter of from about 0.25 inch to about 0.50 inch and a substantially axial bore diameter of from about 0.15 inch to about 0.40 inch. The diameter of the substantially axial bore through the signal control line used in accordance with the present invention is not sufficient to allow commercial quantities of formation fluids to be produced therethrough. The signal control line can be constructed of any suitable material, for example stainless steel or a stainless steel alloy. A signal device refers to a device which is capable of generating one or more unique signals. Nonlimiting examples of a signal device are a radio frequency identification device (RFID), a device carrying a magnetic bar code, a radioactive device, an acoustic device, a surface acoustic wave (SAW) device, a low frequency magnetic transmitter and any other device that is capable of generating one or more unique signals. The signal device can have any suitable peripheral configuration and geometric shape, and is sized to permit conveyance through the signal control line. Some signal devices, for example RFID, can require a peripheral configuration and geometric shape to inhibit tumbling of the RFID during conveyance through the signal control line. A suitable RFID is commercially available from Sokymat SA, Switzerland under the trade name Glass Tag 8 mm Q5. A reader device refers to a device capable of transmitting signals to and receiving signals from a signal device.
(14) In accordance with one embodiment of the present invention as illustrated in
(15) In operation, a suitable signal device 12 can be conveyed from the well head 10 through line 14, for example in suitable fluid, such as hydraulic oil or water, that can be pumped by equipment located at the surface. The signal device 12 is sized and configured to inhibit the signal device from tumbling in line 14 during conveyance (
(16) Each reader device 20 can be programmed to respond to its own unique signal or the same signal of at least one other reader device. As the signal device 12 is conveyed through line 14, the unique signal transmitted thereby can be received and read by each successive reader device. If the unique signal matches that programmed in the reader device, the reader device transmits a control signal to actuate the associated tool 30. Ultimately, the signal device 12 exits through the end of the control line 14 into the well. Thereafter, one or more additional signal devices can be conveyed via control line 14 to actuate one or more tools 30 in any sequence and manner desired. In this manner, an unlimited number of tools can be actuated by conveying one or more signal devices via control line 14. When line 14 is open at end 18 to the well bore, it is subject to hydrostatic fluid, and as such, the hydraulic pressure exerted in this line must be sufficient to overcome this pressure so as to convey signal device 12 through line 14.
(17) In accordance with another embodiment of the present invention as illustrated in
(18) A plurality of tools or equipment 130A, 130B and 130N are positioned in a well and can have a piston or sleeve 132A, 132B and 132N, respectively, moveably secured therein. Each tool 130A, 130B and 130N can be connected to hydraulic line 154 by means of lines 134A, 134B and 134N, respectively, each of which has a corresponding valve 136A, 136B and 136N. Each tool 130A, 130B and 130N can also be connected to hydraulic line 164 by means of lines 138A, 138B and 138N, respectively. Reader devices 120A, 120B and 120N are electrically connected to a suitable power source 124A, 124B, and 124N and antennas 122A, 122B and 122N, respectively. Nonlimiting examples of suitable power sources are batteries. These power sources can be preprogrammed to be in a sleep mode except for certain predetermined periods of time so as to conserve power consumption and therefore extend the life of the power source. As illustrated antennas 122A, 122B and 122N are coiled to surround control line 114 such that the orientation of the signal device 112 within control line 114 is immaterial. Each reader device 120A, 120B and 120N can be electrically connected to corresponding motors 126A, 126B and 126N, respectively, which in turn drive shaft or stem 127A, 127B and 127N to open or close valves 136A, 136B and 136N as will be evident to a skilled artisan. An unlimited number of tools 130 can be controlled by this embodiment of the present invention, with the total number of tools that are positioned in a well and capable of being controlled being designated by the letter N. Hydraulic fluid, such as hydraulic oil or water, can be used in each of the three hydraulic lines and can be pressurized by any suitable means, such as a pump located at or near the well head, to a pressure sufficient to overcome the hydrostatic pressure of fluid present in the well to move from the well head through fluid and signal device 112 a hydraulic line and into the well.
(19) As typically positioned in a well, valves 136A, 136B and 136N are in a closed positioned and pistons 132A, 132B and 132N are positioned to one end of the respective tool 130 as noted by the positions x or y in
(20) In operation, a suitable signal device 112 can be conveyed from the well head 110 through line 114, for example in fluid pumped by equipment located at the surface. Each signal device 112 is programmed to generate a unique signal. Similarly, each reader device 120A, 120B and 120N is programmed to look for a unique code signal. As the signal device 112 passes in proximity to a given reader device 120, the unique signal transmitted by signal device 112 can be received by an antenna 122. If a given reader device 120 is programmed to respond to the signal transmitted by the device 112 via the associated antenna 122, the reader device 120 transmits a corresponding control signal to the associated motor 126 which in turn causes valve 136 to open via shaft 127. Reader devices 120 can also transmit signals which in turn are received by and cause signal device 112 to generate the unique signal. As hydraulic fluid in line 154 is thereby permitted to flow through line 134 and valve 136, the pressure of the hydraulic fluid causes piston 132 in tool 130 to move to the desired position and thereby actuate the tool. Movement of the piston 132 in tool 130 causes the hydraulic fluid on the other side of piston 132 to flow back to the well head 110 via hydraulic line 164. To move piston 132 to a different position, pressure on the hydraulic fluid in line 154 or line 164 can be increased to move the piston with the associated mechanism, such as a collet, thereby permitting the piston to sequentially achieve several positions along the tool 130.
(21) Each reader device 120 can be programmed to respond to its own unique signal or the same signal of at least one other reader device. As the signal device 112 is conveyed through line 114, the unique signal transmitted thereby can be received and read by each successive reader device. If the unique signal matches that programmed in the reader device, the reader device transmits a control signal to open the associated motor 126 and valve 136. Ultimately, the signal device 112 exits through the end of the control line 114 into the well. Thereafter, one or more additional motor(s) 126 and valve(s) 136 in any sequence and manner desired. In this manner, an unlimited number of tools 130 can be actuated by conveying one or more signal devices via control line 114. As line 114 is open at end 118 to the well bore, it is subject to hydrostatic fluid and as such the hydraulic pressure exerted in this line must be sufficient to overcome this pressure so as to convey signal device 112. Alternatively, line 114 can be connected to line 158 thereby permitting passage of signal device 112 to the surface. Signal device 112 can be configured to receive a signal from a given reader device that the unique signal conveyed by the signal device was received by the reader device. In this instance, the reader devices 120 are transceivers permitting each device to receive a unique signal from the signal device and to transmit another unique signal back to the signal device. Each signal device 112 can also be equipped with suitable gauges to measure well, formation, and/or fluid conditions which can then be recorded in signal device 112. Nonlimiting examples of suitable gauges are temperature and pressure gauges. Information contained in the signal device 112 can be read at the surface, erased from the signal device 112, if desired, and the signal device can be programmed to emit another unique signal for use in the same well or another well.
(22) To close each valve 136, each associated reader device can be preprogrammed to actuate the appropriate motor 126 and shaft 127 after a period of time to close the associated valve 136. Alternatively, a signal device 112 can be conveyed via line 114 to transmit a unique signal to the appropriate reader device 120 via antenna 122 which in turn transmits a corresponding control signal to the associated motor 126 causing shaft 127 to close valve 136.
(23) In accordance with another embodiment of the present invention as illustrated in
(24) In the embodiment of the present invention illustrated in
(25) In the embodiment of the present invention illustrated in
(26) Change-over valves 336 are positioned in hydraulic lines 334 and are connected to and controlled by motors 326 and shafts 327. Reader devices 320A, 320B and 320N are electrically connected to a suitable power source 324A, 324B, and 324N and antennas 322A, 322B and 322N, respectively. Nonlimiting examples of suitable power sources are batteries. These power sources can be preprogrammed to be in a sleep mode except for certain predetermined periods of time so as to conserve power consumption and therefore extend the life of the power source. As illustrated, antennas 322A, 322B and 322N are coiled to surround control line 314 such that the orientation of the signal device 312 within control line 314 is immaterial. Each reader device 320A, 320B and 320N is electrically connected to corresponding motors 326A, 326B and 326N, respectively, which in turn drive shaft or stem 327A, 327B and 327N to open or close valves 336A, 336B and 336N as will be evident to a skilled artisan.
(27) Another reader device 380 is electrically connected to a suitable power source 384 and antenna 382 which is configured to surround hydraulic line 314. Reader device 380 is also electrically connected to motors 396 which drives shaft or stem 397 to open or close valve 390 as will be evident to a skilled artisan.
(28) In operation, a signal device 312 can be conveyed via line 314, through open valve 390 and open end 318 into the well for example in fluid pumped by equipment located at the surface. Each signal device 312 is programmed to generate a unique signal. Similarly, each reader device 320A, 320B and 320N is programmed to look for a unique code signal. As the signal device 312 passes in proximity to a given reader device 320, the unique signal transmitted by signal device 312 can be received by an antenna 322. If a given reader device 320 is programmed to respond to the signal transmitted by the device 312 via the associated antenna 322, the reader device 320 transmits a corresponding control signal to the associated motor 326 which in turn causes valve 336 to open via shaft 327. Reader devices 320 can also transmit signals which in turn are received by and cause signal device 312 to generate the unique signal. Antenna 382 conveys a signal received from signal device 312 to actuate motor 396 and shaft 397 to close valve 390. Thereafter, hydraulic fluid in line 314 is thereby permitted to flow through line 334 and valve 336 thereby causing piston 332 in tool 330 to move to the desired position and thereby actuate the tool. Hydraulic fluid flowing around a given piston 332 is permitted to flow back into the well via hydraulic line 338. Reader device 380 can be programmed to cause valve 390 to open a predetermined time after being closed or the unique signal from signal device 312 can contain instructions to cause the reader device to open valve 390 in a predetermined amount of time.
(29)
(30) The following example demonstrates the practice and utility of the present invention, but is not to be construed as limiting the scope thereof.
EXAMPLE 1
(31) A well is drilled to total depth (TD) so as to penetrate a subterranean formation of interest and the drilling assembly is removed from the well. A 7 inch outer diameter intermediate casing is positioned in the well to extend substantially from the surface of the earth to a point above the subterranean formation of interest. The intermediate casing is cemented to the well bore by circulating cement. Excess cement is drilled from the intermediate casing and well bore extending below the intermediate casing through the subterranean zone of interest.
(32) A 3.5 inch outer diameter production casing is equipped with 6 sliding sleeves and has 3 hydraulic lines attached to the outside of the production casing. The sliding sleeves are arranged in series and referred to hereafter as sliding sleeves 1-6, with sliding sleeve 1 being proximal and sliding sleeve 6 being distal the intermediate casing. The hydraulic lines are a control line, a hydraulic power open line and a hydraulic power close line. The end of the production casing has a cementing shoe and a check valve assembly. The production casing and associated equipment and lines is lowered into the well until all sleeves which are in the closed position are in the open hole (portion of the well without intermediate casing).
(33) Water-based, cross-linked fluids are pumped down the production casing and placed in annulus between the production casing and the open hole from TD to above sliding sleeve 1. The fluids are displaced with wiper plug that is conveyed through the production casing and latches in place at the bottom thereof so as to prevent flow of well fluids into the production casing. The fluids are allowed to thicken and create zonal isolation barriers.
(34) A radio frequency identification device (RFID) encoded with specific code is pumped down the control line to actuate the shuttle valve in distal sliding sleeve from the intermediate casing (sleeve 6). Actuation is achieved by means of a radio frequency transceiver associated with the sliding sleeve. Approximately 7 gallons of hydraulic fluid are required to pump the RFID through the control line and into the well. Approximately 3,000 psi pressure is applied via hydraulic fluid in the power open line to open sliding sleeve 6. No pressure should be applied to the power close line so that minor fluid returns can occur as the piston in the sliding sleeve moves positions. After some time period, the shuttle valve in sliding sleeve 6 should close, locking the sleeve in the open position. Thereafter, approximately 3,000 barrels of fluid are pumped through the production casing, open sleeve 6 and into the formation adjacent sliding sleeve 6 so as to fracture and stimulate production of fluids from this adjoining formation. Sand can be incorporated into the stimulation fluid if desired.
(35) Another RFID chip encoded with a specific code down is pumped down control line to actuate the shuttle valve in sliding sleeve 6. Approximately 3,000 psi pressure is applied via hydraulic fluid in the power close line to close sliding sleeve 6. No pressure should be applied to the power open line so that minor fluid returns can occur as the piston in the sliding sleeve moves positions. After some time period the shuttle valve in sliding sleeve 6 should close, locking the sleeve in the closed position. Thereafter, the production casing is pressure tested to confirm integrity. A RFID encoded with a specific code is pumped down the control line to actuate the shuttle valve in sliding sleeve 5. Approximately 3,000 psi pressure is applied to the hydraulic fluid in power open line to open sliding sleeve 5. No pressure should be applied to the power close line so that minor fluid returns can occur as the piston in the sliding sleeve moves positions. After some time period the shuttle valve in sliding sleeve 5 should close, locking the sleeve in the open position.
(36) Thereafter, approximately 3,000 barrels of fluid are pumped through the production casing, open sleeve 5 and into the formation adjacent sliding sleeve 5 so as to fracture and stimulate production of fluids from this adjoining formation. Sand can be incorporated into the stimulation fluid if desired.
(37) Another RFID chip encoded with a specific code down is pumped down control line to actuate the shuttle valve in sliding sleeve 5. Approximately 3,000 psi pressure is applied via hydraulic fluid in the power close line to close sliding sleeve 5. No pressure should be applied to the power open line so that minor fluid returns can occur as the piston in the sliding sleeve moves positions. After some time period the shuttle valve in sliding sleeve 5 should close, locking the sleeve in the closed position. Thereafter, the production casing is pressure tested to confirm integrity. This process is repeated for sliding sleeves 4, 3, 2, and 1 respectively.
(38) After the formation adjacent each of sleeves 1-6 has been stimulated, the cross-linked fluids are permitted to break down thereby removing the isolation barriers. Separate RFIDs are pumped down the control line to open and allow the well to be flow tested sequentially open sleeves 1, 2, 3, 4, 5, and 6 in order, while applying pressure to power open line and holding no back pressure on the power close line. The production casing and associated sleeves and lines can then be retrieved from the well, after circulating fluid down the production casing and up annulus. Thereafter, the well completion operations are continued.
(39) Although the antennae of the present invention has been illustrated in
(40) While the foregoing preferred embodiments of the invention have been described and shown, it is understood that the alternatives and modifications, such as those suggested and others, can be made thereto and fall within the scope of the invention.