System for the operational and performance efficiency improvement of wireline tractors
11608697 · 2023-03-21
Inventors
Cpc classification
F15B11/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B23/14
FIXED CONSTRUCTIONS
F04B53/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F15B2211/465
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F15B2211/7053
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H48/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B23/00
FIXED CONSTRUCTIONS
F16H1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B53/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B23/001
FIXED CONSTRUCTIONS
F04B47/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K9/193
ELECTRICITY
International classification
E21B23/00
FIXED CONSTRUCTIONS
E21B17/10
FIXED CONSTRUCTIONS
F15B11/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H48/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16H1/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
The invention discloses systems for improving performance and operational efficiency of wireline tractors. A cooling system improves power capabilities of electrical motors mounted in wheels, which are mounted on a linkage pivotably connected to an arm extended from a tractor tool body, in an in-line arm configuration. The linkage and arm mechanism significantly improve the tractor's ability to traverse wellbore obstructions. The hydraulic system of the tractor ensures adequate wellbore centralization.
Claims
1. A downhole tractor mechanism for deployment via a wireline in a subterranean formation comprising: an arm radially extendable from a tractor tool body; the tractor tool body connected to the wireline; a linkage having a single pivot point, a first free end and an opposing second free end, and mounted to an extendable end of the arm at the pivot point; a first drive wheel mounted to the linkage at the first free end and a second drive wheel mounted to the linkage at the second free end; the distance from the pivot point to the first free end differing from the distance from the pivot point to the second free end; the first and second drive wheel disposed to contact the inside of a tubular and apply a traction force thereto; a gear train within the arm; the gear train within the arm arranged to transmit power to a gear train within the linkage; the gear train within the linkage arranged to transmit power to the drive wheels.
2. The mechanism of claim 1, wherein the first drive wheel comprises an electric motor.
3. The mechanism of claim 1, further comprising a gear differential within the gear train within the linkage.
4. The mechanism of claim 3, wherein the gear differential is a limited slip differential.
5. A downhole tractor mechanism comprising: an arm radially extendable from a tractor tool body; a linkage having a single pivot point, a first free end and an opposing second free end, and mounted to an extendable end of the arm at the pivot point; a first drive wheel mounted to the linkage at the first free end and a second drive wheel mounted to the linkage at the second free end; the distance from the pivot point to the first free end differing from the distance from the pivot point to the second free end; the first and second drive wheel disposed to contact the inside of a tubular and apply a traction force thereto; a gear train within the arm; the gear train within the arm arranged to transmit power to a gear train within the linkage; the gear train within the linkage arranged to transmit power to the first and second drive wheel.
6. The mechanism of claim 5, further comprising a gear differential within the gear train within the linkage.
7. The mechanism of claim 6, wherein the gear differential is a limited slip differential.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(27) The present invention will be described in connection with its preferred embodiments. However, to the extent that the following description is specific to a particular embodiment or a particular use of invention, this is intended to be illustrative only, and is not to be construed as limiting the scope of the invention. On the contrary, the description is intended to cover all alternatives, modifications, and equivalents that are included within the spirit and scope of the invention, as defined by the appended claims.
(28) The present invention describes a system to improve the operational and performance efficiency of downhole tractors. The benefits of reducing the temperature of electrical motors and electrical components are numerous. For downhole tractors and other mechanical intervention tools cooling motors within these tools can substantially increase their power output capability. Cooling also increases the life of materials susceptible to degradation by exposure to heat. Additionally, cooling materials can allow a designer to design near the ultimate strength of the material, without necessitating a de-rating factor for the material at high temperature. In an embodiment, a downhole tool comprises several tool modules or sections which may consist of one or more of; a cable head; hydraulic module including an electrical motor which powers a hydraulic pump. The pump may provide hydraulic fluid into a hydraulic line which is routed through a heat exchange section; through a motor section, which may comprise an electrical motor; through an electronics section, which may contain a motor controller; and into an accumulator section. From the accumulator section, a hydraulic line may be routed into the opposite direction and returned by a hydraulic return line, through the motor section; through the electronics section; through an electrical motor in the motor section; through a heat exchange section and into hydraulic module; to the return port of hydraulic pump. As hydraulic fluid is pumped through the electrical motors, heat may be transferred to the hydraulic fluid which passes therethrough. Hydraulic fluid may enter the heat exchange section and heat may be transferred to the ambient wellbore environment.
(29) In an embodiment, the hydraulic module may additionally provide hydraulic fluid via a hydraulic line to sections of the downhole tool for hydraulic actuation purposes.
(30) In an embodiment, the accumulator section may also function as a heat exchange section to further manage heat generated within the downhole tool.
(31) In an embodiment, the downhole tool modules are within a common housing, which together comprise a system for cooling components in the downhole tool.
(32) In an embodiment, a temperature sensing device is disposed to sense the temperature of a heat generating component within the downhole tool.
(33) In an embodiment, a temperature sensing device is disposed to sense the heat of a hydraulic passage or other passage.
(34) In an embodiment, a parameter sensing device is disposed to sense a parameter of a heat generating component.
(35) In a further embodiment, a second temperature sensing device is disposed to sense a second temperature within the downhole tool or exterior the downhole tool.
(36) In a further embodiment, a second parameter sensing device is disposed to sense a second parameter within the downhole tool or exterior the downhole tool.
(37) In an embodiment one or more parameter sensing devices are disposed to provide communication with an electrical controller within the electronics section.
(38) In an embodiment, the downhole tool further comprises a hydraulic control block disposed to received hydraulic fluid from the hydraulic pump. The hydraulic control block may include hydraulic components which may control one or more of; flow, pressure and direction of the hydraulic fluid.
(39) In an embodiment, the hydraulic control block contains hydraulic components selected from one or more of; solenoid valves, check valves, relief valves, pilot-operated check valves, shuttle valves, flow regulators, pressure regulators or other hydraulic components.
(40) In an embodiment, one or more of the hydraulic components within the hydraulic control block may reside in another portion of the downhole tool, exterior the hydraulic control block.
(41) In an embodiment, a hydraulic control circuit is provided which includes functionality to provide hydraulic fluid for actuation of pistons and for thermal management purposes. A pump may deliver hydraulic fluid to one or more fluid regulators disposed to regulate flow for each purpose. On the actuation side of the hydraulic control circuit, a set of solenoid valves and pilot operated check valves may be operated to control the direction of flow to a corresponding actuation and retraction of pistons, thereby allowing for continuous thermal management with the ability to simultaneously control actuation pistons.
(42) In a preferred embodiment, one or more flow passages are disposed to receive fluid from the outlet of the hydraulic pump. A solenoid valve may be disposed to control flow therethrough such that upon energizing the solenoid valve on a first passage, flow is blocked from entering a thermal management system and when a solenoid valve is energized on a second passage, flow is delivered to one or more actuation pistons.
(43) In an embodiment, the pistons may be disposed to actuate one or more tractor arms.
(44) In an embodiment, the pistons may be disposed to actuate one or more members to engage with the interior of a well bore.
(45) In an embodiment, the flow through the electrical motors may flow through a rotor passageway, around or parallel to the long axis of the stator, through an annular space or any combination thereof.
(46) In an embodiment, a method is provided for dissipating heat from within a downhole tool. The method comprises, delivering fluid from a pump outlet to a first hydraulic passage routed through one or more tool sections containing heat generating components; through one or more heat exchanging sections of the downhole tool disposed to dissipate heat to a region exterior the downhole tool; and to the pump intake.
(47) In an embodiment, the method further comprises controlling the flow of the fluid to the first hydraulic passage.
(48) In an embodiment, the method further comprises monitoring a parameter of a heat generating component within the downhole tool; controlling the flow of fluid to the first hydraulic passage based on the parameter of the component reaching a setpoint parameter. Optionally, a parameter of a non-heat generating component or material may be monitored within or exterior to the downhole tool. For example, the wellbore temperature may be monitored.
(49) In an embodiment, the method comprises monitoring the temperature of a hydraulic passage; controlling the flow of fluid to the first hydraulic passage based on the temperature of the passage reaching a setpoint temperature.
(50) In an embodiment, the method further comprises the parameter sensing device providing a signal to a controller such that the controller may deliver a signal to surface based on the parameter sensing device signal. Optionally, the controller may deliver a signal to a component within the downhole tool, for example, a motor coupled to a hydraulic pump or a solenoid operated valve, to control the flow of fluid to the first hydraulic passage.
(51) The controller may be an analog circuit or a digital processor, such as an application specific integrated circuit (ASIC) or array of field-programmable gate arrays (FPGAs). Accordingly, embodiments may implement any one or more aspects of control logic in the controller that is on-board the downhole tool or in a computing system that is in data communication with the controller. A computing system may be located at the surface to provide a user-interface for monitoring and controlling the operation of the downhole tool and may be in data communication with the controller over a wireline cable.
(52) In an embodiment, a second parameter sensing device signal is provided to the controller and the controller provides a signal to control the flow of fluid based on a comparison of signals provided by the first and second parameter sensing device.
(53) In an embodiment, the method further comprises controlling the flow of fluid to a second hydraulic passage.
(54) In an embodiment, the parameter is temperature.
(55) In an embodiment, the parameter is current.
(56) In an embodiment, the heat generating component is an electrical motor.
(57) In an embodiment, the heat generating component is a battery.
(58) In an embodiment, the heat generating component is a transformer.
(59) In an embodiment, the heat generating component is a transistor.
(60) In an embodiment, the heat generating components is a processor.
(61) A downhole tractor tool may have in-line or side by side arms with powered wheels mounted to the ends of the arms and disposed to receive mechanical power to apply a traction force to a wellbore wall. In an embodiment, a linkage may be disposed at the end of each arm with a powered wheel at each end of the linkage. In this manner, the tractor is well suited to traverse obstructions within a wellbore. When a first wheel at an end of the linkage enters an obstruction, the second wheel may still be unaffected by the obstruction and thereby ensure that both wheels traverse the obstruction.
(62) In an embodiment, the point at which the linkage is connected to the arm is off-center of the linkage.
(63) In an embodiment, mechanical power is transmitted to the wheels by a gear train within the arm and disposed to receive mechanical power from a motor within the tractor. The gear train within the arm may transmit mechanical power to a gear train within the linkage.
(64) In an embodiment, the gear train within the arm transmits power to a differential and each wheel powered by an output of the differential.
(65) In an embodiment, a motor is disposed within each wheel and receives electrical energy from within the downhole tractor tool body.
(66) In an embodiment, a method is provided for conveying a bottom hole assembly across a wellbore obstruction. The method comprising, deploying a bottom hole assembly including a downhole tractor within a wellbore; activating the downhole tractor to tractor the bottom hole assembly to an obstruction; deploying one or more arms of the tractor and activating one or more motors to power a first and second drive wheel disposed on distal ends of a linkage secured to each tractor arm; engaging the obstruction with the first downhole wheel; the first downhole wheel traversing all or part of the obstruction; engaging the obstruction with the second drive wheel and traversing part of the obstruction; the second drive wheel traversing the obstruction; continuing to tractor the bottom hole assembly such that each arm and associated linkage has passed across the obstruction; continuing to tractor the bottom hole assembly such that the bottom hole assembly crosses the obstruction.
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(68) In a second embodiment represented by
(69) A hydraulic control block 18 in
(70) As mentioned, the hydraulic pump 9 may also be used for various actuation functions within the tool.
(71) Electrical motors 10 and 11, may in other embodiments reside in the arm or in the wheel of a tractor motor.
(72) Additionally, in
(73) In a preferred embodiment of the hydraulic control circuit, represented in
(74) Additionally, in
(75) In all embodiments described above, flow through electrical motors 10 and 11 as shown by motor 31 in
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(77) Improving upon the state of the art by incorporating an additional wheel per arm offers significant advantages for traversing perforation holes and other obstacles within the wellbore. Representative in-line arm tractor section 45 of
(78) For clarity in
(79) Radial force is applied to wellbore 37 for traction by arm 51 to linkage 50 and thereby to drive wheels 48 and 49. Due to the off-center connection of arm 51 to linkage 50, the forces exerted by each wheel to the wellbore 37, on a uniform surface, are of differing magnitude as represented by large arrow 47 and smaller arrow 46.
(80) When the tractor arm mechanism interacts with a step in the wellbore 37 a reaction force 53 is exerted which creates a moment about pivot point 52 causing an increase in force 47. This relationship is ideal to lift wheel 49 on top of the step in the wellbore because additional traction is now available to wheel 48 due to the now increased radial force 47 of
(81) There are several configurations of in-line arm tractors, two of which are shown in
(82) A close-up view of the tractor mechanism of
(83) In the embodiment of
(84) An embodiment of the tractor arm mechanism of
(85) Unlike side-by-side arms that are mechanically linked. The actuation of tractor arms in an in-line arm configuration must be controlled differently to ensure adequate centralization of the tractor in the wellbore.
(86) One method for eliminating the problem of centralizing an in-line arm tractor is to charge a high volume-high pressure accumulator and release the accumulated hydraulic energy into the actuation cylinders of the tractor arms. This may overcome the resting inertia of the tractor tool resting on the wellbore such that each actuation cylinder receives hydraulic fluid to adequately centralize the tractor tool.
(87) A preferred solution is shown by the hydraulic circuit in
(88) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the claims. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the embodiment. The term “seal”, as in the engaging of a sealing element to a borehole, is used for the purpose of describing particular embodiments.
(89) The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. Embodiments have been presented for purposes of illustration and description, but it is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art after reading this disclosure. The disclosed embodiments were chosen and described as non-limiting examples to enable others of ordinary skill in the art to understand these embodiments and other embodiments involving modifications suited to a particular implementation.