Method and apparatus for dual instrument installation in a wellbore

Abstract

An apparatus for installing two sensing instruments and cables inside of a single tubing string in a wellbore for monitoring well conditions at two different locations includes an upper sensor attached to an inner sleeve seated at a first location in a ported outer sleeve in the tubing string. The upper sensor is allowed to be in pressure communication with the exterior of the tubing string at the first location. A second lower sensor is deployed on a pump down cup (PDC) assembly to a lower depth in the outer sleeve to allow fluid pressures to be monitored at a second location in the wellbore.

Claims

1. An apparatus for deploying at least two sensing instruments at different locations in a tubing string within a wellbore comprising: an outer sleeve for operative connection to the tubing string; an inner sleeve connected to a first sensing instrument, the inner sleeve for engagement with the outer sleeve at a first location; and a pump down assembly connected to a second sensing instrument, the pump down assembly disengageably connected to the inner sleeve and moveable through the tubing string with the inner sleeve to the first location; wherein applying fluid pressure in the tubing string disengages the pump down assembly from the inner sleeve at the first location, and applying further fluid pressure in the tubing string moves the pump down assembly and the second sensing instrument through the tubing string to a second location.

2. The apparatus of claim 1 wherein the first and second sensing instruments are pressure sensors and are in pressure communication at the first and second locations, respectively, with the exterior of the tubing string.

3. The apparatus of claim 1 wherein the outer sleeve includes at least one outer sleeve port for enabling pressure communication between the first sensing instrument and the exterior of the tubing string.

4. The apparatus of claim 3 wherein the inner sleeve includes an inner sleeve port positioned adjacent the first sensing instrument and in pressure communication with the at least one outer sleeve port for enabling pressure communication between the first sensing instrument and the exterior of the outer sleeve.

5. The apparatus of claim 4 wherein the inner sleeve further comprises an orifice located between the inner sleeve port and the first sensing instrument for enabling pressure communication between the first sensing instrument and the inner sleeve port.

6. The apparatus of claim 4 wherein the interior of the outer sleeve further comprises a circumferential groove within which the at least one outer sleeve port is located, and wherein the groove defines a recess between the at least one outer sleeve port and the inner sleeve port for allowing fluid communication between the at least one outer sleeve port and the inner sleeve port regardless of the orientation of the inner sleeve port within the recess.

7. The apparatus of claim 6 further comprising a plurality of outer sleeve ports located in the circumferential groove, and wherein the recess enables the plurality of outer sleeve ports to be in fluid communication with each other and with the inner sleeve port.

8. The apparatus of claim 1, further comprising at least one seal located between the inner sleeve and the outer sleeve for sealing the first sensing instrument from the inside of the inner sleeve.

9. The apparatus of claim 1, wherein the first and second sensing instruments are sensors for measuring fluid pressure and/or temperature.

10. The apparatus of claim 1, wherein the pump down assembly is disengageably connected to the inner sleeve by a shear sub, and applying fluid pressure into the tubing string causes the shear sub to shear, disengaging the pump down assembly from the inner sleeve at the first location.

11. The apparatus of claim 1, wherein the pump down assembly includes a pump down cup for pumping the pump down assembly from the first location to the second location using fluid pressure.

12. The apparatus of claim 11 wherein the pump down cup includes a heat dissolvable material.

13. The apparatus of claim 11 wherein the heat dissolvable material is urethane that melts at temperatures of around 100° C.

14. The apparatus of claim 11, wherein the pump down cup includes a plurality of outwardly extending cups for engagement with the interior of the tubing string for enabling the pump down assembly to be pumped from the first location to the second location.

15. The apparatus of claim 1, wherein the pump down assembly further comprises a bullnose for guiding the pump down assembly through the tubing string.

16. The apparatus of claim 1, wherein the pump down assembly has an outer surface containing at least one groove for creating turbulence in a pumping fluid.

17. The apparatus of claim 16 wherein there are a plurality of longitudinal grooves in the pump down assembly outer surface.

18. The apparatus of claim 1, wherein the first and second sensing instruments are attached to a first and second cable, respectively, that extend from the sensing instruments to a well surface.

19. The apparatus of claim 1, wherein the outer sleeve further comprises a restriction at the second location for landing the pump down assembly at the second location in the tubing string.

20. The apparatus of claim 1, further comprising at least one perforation in the tubing string adjacent the second sensing instrument at the second location for enabling fluid communication between the second sensing instrument and the exterior of the tubing string.

21. A method for deploying two sensing instruments at different locations in a tubing string within a wellbore comprising the steps of: a) operatively connecting an outer sleeve to a tubing string and running the outer sleeve and tubing string into the wellbore; b) running an inner sleeve and a pump down assembly down the tubing string, the inner sleeve connected to a first sensing instrument and the pump down assembly connected to a second sensing instrument, wherein the pump down assembly is disengageably connected to the inner sleeve; c) seating the inner sleeve and first sensing instrument in the outer sleeve at a first location in the tubing string; d) applying fluid pressure into the tubing string to disengage the pump down assembly from the inner sleeve at the first location; and e) applying further fluid pressure into the tubing string to pump the pump down assembly and second sensing instrument through the tubing string from the first location to a second location; wherein the first and second sensing instruments are in pressure communication with the exterior of the tubing string at the first and second locations, respectively.

22. The method of claim 21 wherein in step d), the pump down assembly is disengaged from the inner sleeve by shearing.

23. The method of claim 21, further comprising the step of: f) injecting steam into the tubing string to cause at least a portion of the pump down assembly to melt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described with reference to the accompanying figures in which:

(2) FIG. 1 is a schematic of a horizontal wellbore illustrating a typical dual sensor installation in accordance with the prior art.

(3) FIG. 2 is a schematic of a horizontal wellbore illustrating a dual sensor installation scenario in accordance with one embodiment of the invention.

(4) FIG. 3 is a cross-sectional side view of a dual instrumentation apparatus with an inner sleeve seated in an outer sleeve, and a pump down cup assembly (PDC) in the run-in position wherein the pump down cup assembly is attached to the inner sleeve at a first location in the tubing string in accordance with one embodiment of the invention.

(5) FIG. 4 is a cross-sectional side view of a dual instrumentation apparatus with the inner sleeve seated in the outer sleeve, and the pump down cup assembly in the set position wherein it has been released from the inner sleeve and pumped to a second location in the tubing string in accordance with one embodiment of the invention.

(6) FIG. 5 is a side view of the outer sleeve at the first location in the tubing string with the internal profile illustrated in accordance with one embodiment of the invention.

(7) FIG. 6A is a top view of the inner sleeve showing the orifice and the upper sensor at the first location in the tubing string in accordance with one embodiment of the invention.

(8) FIG. 6B is a cross-sectional side view of the inner sleeve at 6B-6B of FIG. 6A in accordance with one embodiment of the invention.

(9) FIG. 7A is a side view of a shear sub with an internal profile illustrated in accordance with one embodiment of the invention.

(10) FIG. 7B is a bottom view of the shear sub with the internal profile illustrated in accordance with one embodiment of the invention.

(11) FIG. 8 is a side view of the pump down cup (PDC) mandrel in accordance with one embodiment of the invention.

(12) FIG. 9 is a side view of the pump down cup (PDC) with the internal profile illustrated in accordance with one embodiment of the invention.

(13) FIG. 10A is a side view of a retainer nut with the internal profile illustrated in accordance with one embodiment of the invention.

(14) FIG. 10B is a bottom view of the retainer nut with the internal profile illustrated in accordance with one embodiment of the invention.

(15) FIG. 11 is a cross-sectional side view of the PDC assembly in the set position at the second location in the tubing string, showing the flow of pump down fluid from the interior to the exterior of the outer sleeve in accordance with one embodiment of the invention.

(16) FIG. 12 is a cross-sectional side view of the PDC assembly in the set position at the second location in the tubing string after the PDC has dissolved in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(17) With reference to the figures, a dual instrumentation apparatus 10 and method of deploying the apparatus in a wellbore are described.

(18) FIG. 2 is a schematic of a horizontal wellbore 1 showing one embodiment of the dual instrumentation apparatus 10. The apparatus 10, contained within a well casing 1, comprises a tubing string 5 containing two cables 3, 7 containing wires that extend from instrumentation at the surface of the well to a lower sensor 2 and an upper sensor 6 in the apparatus. In FIG. 2, the upper sensor 6 is located near the heel 9 of the wellbore at a first location, and the lower sensor 2 is positioned further downhole at a second location near the toe 4 of the wellbore. In alternate embodiments, the upper and lower sensors may be positioned at other locations in the wellbore. For example, the lower sensor may be located further uphole instead of at the end of the tubing string. Alternatively, the lower sensor may be positioned out the end of the tubing string.

(19) FIG. 2 illustrates the dual instrumentation apparatus installed in a horizontal wellbore, however the apparatus can also be installed in other types of wellbores such as vertical and deviated wellbores.

(20) Referring to FIG. 3, the apparatus comprises an inner sleeve 12 seated inside an outer sleeve, which is integral with the utility tubing, and a pump down cup (PDC) assembly 16 attached to the inner sleeve. The entire PDC assembly is moveable between a run-in position, shown in FIG. 3, and a set position, shown in FIGS. 4 and 11. The upper sensor 6 is attached to the inner sleeve, and the lower sensor is retained on the PDC assembly.

(21) Outer Sleeve

(22) Referring to FIG. 5, outer sleeve includes an outer surface 14g, an inner surface 14a defining a cavity 14d, a plurality of ports 14b, an inner shoulder 14e, and a groove 14f.

(23) The outer sleeve inner shoulder 14e is located on the inner surface 14a of the cavity 14d to provide a landing point for the inner sleeve 12. The ports 14b extend through the outer sleeve around the outer sleeve circumference in the groove 14f. When the inner sleeve is landed in the outer sleeve, the groove 14f creates a recess 14i (shown in FIGS. 3 and 4) between the inner and outer sleeves to allow all the ports 14b to be in pressure communication with each other and with a port 12b on the inner sleeve. The groove and recess allow the inner sleeve port to be orientated in any manner within the recess and be in fluid communication with all the outer sleeve ports. The multiple ports also ensure fluid communication between the upper sensor and the exterior of the outer sleeve is maintained in the event that one or more of the ports 14b becomes plugged.

(24) Inner Sleeve

(25) Referring to FIGS. 6A and 6B, the inner sleeve 12 includes an outer surface 12g, an inner surface 12c defining a cavity 12d, an upper end 12i, a lower end 12j, an orifice 12a, a port 12b, an inner shoulder 12e, an outer shoulder 12k, seal recesses 12f, retainer holes 12h, and a protrusion 12m.

(26) The orifice 12a extends longitudinally from the inner sleeve upper end between the outer surface and the inner surface. The upper sensor 6 is connected to an upper end 12m of the orifice and is in sealing engagement with the orifice. In one embodiment, shown in FIG. 6B, the orifice extends beyond the upper end of the inner sleeve for ease of connection of the upper sensor. That is, the extension of the orifice upper end allows the upper sensor and cable to be threaded (for example) onto the extension using a wrench or similar device.

(27) The port 12b extends from the orifice to the outer surface of the inner sleeve to allow the upper sensor to be in pressure communication with the exterior of the outer sleeve. The seal recesses 12f are located in the outer surface of the inner sleeve and contain sealing elements 28, such as O-rings, to seal the port and upper sensor from the inside of the inner and outer sleeves. The outer shoulder 12k, located on the outer surface of the inner sleeve, abuts with the outer sleeve inner shoulder 14e for landing the inner sleeve 12 within the outer sleeve 14 at the first location. The inner shoulder, located on the inner surface of the inner sleeve, allows for a shear sub 22 (described below) to be positioned in the inner sleeve cavity. The shear sub is affixed within the cavity using shear pins or screws that are installed through the inner sleeve retainer holes 12h and corresponding shear sub retainer holes.

(28) Pump Down Cup (PDC) Assembly

(29) Referring to FIGS. 3 and 4, the PDC assembly 16 includes a PDC mandrel 18, a PDC 20, a shear sub 22, and a retainer nut 26.

(30) Referring to FIG. 8, the PDC mandrel 18 is the core of the PDC assembly 16 and includes an upper end 18a, a central region 18b a lower end 18c, an upper hole 18d and a lower hole 18e. Preferably, the lower sensor 2 is threaded onto the upper end of the mandrel. The shear sub 22 is retained on the central region 18b, near the upper end 18a, and held in place using pins or screws inserted through the upper hole 18d. The PDC 20 is also retained on the central region, below the shear sub 22. The retainer nut 26 is connected to the lower end 18c of the PDC mandrel and held in place using pins or screws inserted through the lower hole 18e.

(31) Referring to FIGS. 7A and 7B, the shear sub 22 of the PDC assembly includes a sleeve 22c having an outer surface 22d, an internal bore 22e, an upper end 22b, a lower end 22f, longitudinal grooves 22g, shear pins 22a retained within shear pin holes 22h, a retainer hole 22i, and a shear sub seal groove 22j. At least a portion of the shear sub is retained within the inner sleeve 12 when the PDC assembly is in the run-in position at the first location in the outer sleeve, and the shear pins 22a extend into the inner sleeve retainer holes 12h. When pressure is applied to the shear sub upper end 22b, the shear pins 22a shear, releasing the shear sub from the inner sleeve and allowing the entire PDC assembly and lower sensor 2 to be pumped downhole into the set position at the second location. The longitudinal grooves 22g on the shear sub outer surface 22d create turbulence in the pump fluid to aid in pumping the PDC assembly downhole. The PDC mandrel 18 is inserted into the shear sub internal bore 22e and secured in place using pins or screws extending through the shear sub retainer hole 22i. The shear sub seal groove 22j is located upstream of the shear pins 22a and contains a shear sub seal (not shown) for preventing fluid leakage around the shear sub outer surface when the PDC assembly is in the run-in position.

(32) Referring to FIG. 9, the PDC 20 includes a sleeve 20a having an inner bore 20b and a plurality of cups 20c each having an upper surface 20d and an outer surface 20c. The PDC is used to pump the PDC assembly downhole after the shear sub has sheared by applying fluid pressure onto the upper surface 20d of the cups 20c, pushing the PDC assembly downhole. The outer surface of each cup is in engagement with the outer sleeve inner surface 14a during run-in of the dual instrumentation apparatus, and then in engagement with the internal diameter of the tubing string after the PDC assembly has been sheared from the inner mandrel with pump pressure and is being pumped downhole. Other shapes and configurations for the PDC may be used as would be known to one skilled in the art. In one embodiment, a portion of the PDC is made from a material that melts or dissolves at high temperatures to enable subsequent fluid flow around the PDC if desired. In this embodiment, a portion of the PDC comprises a dissolvable material such as urethane may be incorporated, which melts at a temperature of 108° C.

(33) Referring to FIGS. 10A and 10B, the PDC retainer nut 26 includes a body 26a having an outer surface 26b, a bore 26d, an upper end 26c, a bull nose 26g, a retainer hole 26e, and a plurality of grooves 26f. The PDC mandrel 18 is inserted into the bore 26d and attached via a pin or screw inserted through a hole 26e in the retainer nut body that lines up with the PDC mandrel lower hole 18e. The bull nose 26g guides the PDC assembly down the tubing string and provides protection for the rest of the PDC assembly and lower sensor. Similar to the shear sub 22, the PDC retainer nut grooves 26f create turbulence in the pump-down fluid to aid in the pumping down process in order to move the PDC assembly from the run-in position to the set position, and from the first location to the second location in the tubing string.

(34) Setting the Pump Down Cup (PDC) Assembly

(35) FIGS. 11 and 12 illustrate a lower section 14k of the tubing string wherein the PDC assembly and the lower sensor are set at the second location. The lower section 14k of the tubing string is a specialized section or sleeve that includes a restriction in the tubing string that prevents the PDC assembly from going past the desired location and that includes perforations to permit fluid flow through the lower section 14k. In one embodiment, the restriction is an internal diameter restriction in the tubing string. In another embodiment, there is a bar (not shown), such as a tag bar, extending across the internal cavity of the tubing string to act as a restriction. Other suitable mechanisms for setting the PDC assembly and lower sensor at the desired location are known to one skilled in the art.

(36) As noted above, the lower section 14k of the tubing string also includes perforations 14h for allowing the lower sensor to be in fluid and pressure communication with the exterior of the tubing string.

(37) Method

(38) In operation, the tubing string is prepared by connecting the lower section 14k to the end of the tubing string as well as connecting the outer sleeve 14 to the tubing string at a desired position. The tubing string is run into a wellbore, typically such that the lower section 14k is adjacent the toe and the outer sleeve 14 is adjacent the heel of the wellbore thereby defining the first and second positions. At the well surface. the upper sensor cable 7 and upper sensor 6 are attached in the inner sleeve orifice 12a, and the lower sensor 2 and lower sensor cable 3 are attached to the PDC mandrel 18. The PDC assembly is connected to the inner sleeve, and the inner sleeve and PDC assembly are pumped into the tubing string until they land at the first location in the outer sleeve,

(39) Upon seating of the inner sleeve in the outer sleeve, pumping fluid pressure is increased, shearing the shear sub 22 and releasing the PDC assembly from the inner sleeve. Pumping is continued, causing the PDC assembly and attached lower sensor 2 and cable 3 to move downhole to the second location where the restriction 32 prevents the PDC assembly from moving beyond the desired depth/location. Upon seating the PDC assembly in the outer sleeve at the second location, pumping is stopped and the PDC is now in the set position at the second location. The pump down fluid flows out of the outer sleeve cavity 14d through the perforations 14h where it is pumped back to the surface for recovery.

(40) In one embodiment, after the PDC assembly has reached the desired depth/location and is in the set position, high temperature fluid or steam is injected into the tubing string to cause the PDC to melt or dissolve. FIG. 12 illustrates the PDC assembly in the set position after the PDC has melted/dissolved.

(41) Alternative Uses for the Dual Instrumentation Apparatus

(42) While the dual instrumentation apparatus has been described as deploying an upper and lower sensor for measuring pressure and temperature of wellbore fluid, the apparatus may be used for other purposes. For example, the apparatus can be used to inject substances into the well at different depths. Instead of cables containing wires attached to sensors there are hollow cables into which chemicals or other substances are injected that would then be introduced to different depths in the wellbore. In another embodiment, instead of measuring pressure at a first and second location using sensors and cables, “bubble tubes” are used to monitor downhole pressure at the first and second location. Bubble tubes, as known to one skilled in the art, are hollow cables that allow pressure access from one end of the tube to the other end of the tube.

(43) In a further embodiment, the apparatus can be used for taking fluid samples from different depths in the well. Again, in this embodiment the system would not include sensors but rather just hollow cables.

(44) Although the present invention has been described and illustrated with respect to preferred embodiments and preferred uses thereof, it is not to be so limited since modifications and changes can be made therein which are within the full, intended scope of the invention as understood by those skilled in the art.