US 7055592 B2
An induction choke in a petroleum well where a voltage potential is developed across the choke to power and communicate with devices and sensors in the well. Preferably, the induction choke is a ferromagnetic material and acts as an impedance to a time-varying current, e.g. AC. The petroleum well includes a cased wellbore having a tubing string positioned within and longitudinally extending within the casing. A controllable gas lift valve, sensor, or other device is coupled to the tubing. The valve sensor, or other device is powered and controlled from the surface. Communication signals and power are sent from the surface using the tubing, casing, or liner as the conductor with a casing or earth ground. For example, AC current is directed down a casing or tubing or a lateral where the current encounters a choke. The voltage potential developed across the choke is used to power electronic devices and sensors near the choke. Such induction chokes may be used in many other applications having an elongated conductor such as a pipe, where it is desirable to power or communicate with a valve, sensor, or other device without providing a dedicated power or communications cable.
1. A passive impedance device for creating a voltage differential when time variant current is applied to a tubular connected to a top and bottom connection to the passive impedance device, the passive impedance device comprising:
a tubular having a threaded connection at a first end of the tubular and a threaded connection at a second end of the tubular;
a plurality of subsections surrounding the tubular, each subsection comprising a plurality of layers of a ferromagnetic alloy, each layer separated by an electrically insulating material;
a non-electrically conductive insulator between each of the subsections; and
a protective covering over the plurality of subsections.
2. The passive impedance device of
3. The passive impedance device of
4. The passive impedance device of
5. The passive impedance device of
6. The passive impedance device of
7. The passive impedance device of
8. The passive impedance device of
9. The passive impedance device of
10. The passive impedance device of
11. The passive impedance device of
This is a continuation of application Ser. No. 09/769,047 filed Jan. 24, 2001, the entire disclosure of which is hereby incorporated by reference.
This application claims the benefit of the U.S. Provisional Applications in the following table, all of which are hereby incorporated by reference:
The present invention relates to the use of a ferromagnetic choke in a petroleum well where a voltage potential is developed across the choke to power and communicate with devices and sensors in the well.
The current application shares some specification and figures with the following commonly owned and concurrently filed applications in the following table, all of which are hereby incorporated by reference:
Several methods have been devised to place controllable valves and other devices and sensors downhole on the tubing string in a well, but all such known devices typically use an electrical cable along the tubing string to power and communicate with the devices and sensors. It is undesirable and in practice difficult to use a cable along the tubing string either integral with the tubing string or spaced in the annulus between the tubing and the casing because of the number of failure mechanisms present in such a system. Other methods of communicating within a borehole are described in U.S. Pat. Nos. 5,493,288; 5,576,703; 5,574,374; 5,467,083; 5,130,706.
U.S. Pat. No. 6,070,608 describes a surface controlled gas lift valve for use in oil wells. Methods of actuating the valve include electro-hydraulic, hydraulic, and pneumo-hydraulic. Sensors relay the position of the variable orifice and critical fluid pressures to a panel on the surface. However, when describing how electricity is provided to the downhole sensors and valves, the means of getting the electric power/signal to the valves/sensors is described as an electrical conduit that connects between the valve/sensor downhole and a control panel at the surface. U.S. Pat. No. 6,070,608 does not specifically describe or show the current path from the device downhole to the surface. The electrical conduit is shown in the figures as a standard electrical conduit, i.e., an extended pipe with individual electrically insulated wires protected therein, such that the pipe provides physical protection and the wires therein provide the current path. But such standard electrical conduits can be difficult to route at great depths, around turns for deviated wells, along multiple branches for a well having multiple lateral branches, and/or in parallel with coil production tubing. Hence, there is a need for a system and method of providing power and communications signals to downhole devices without the need for a separate electrical conduit filled with wires and strung along side of production tubing.
U.S. Pat. No. 4,839,644 describes a method and system for wireless two-way communications in a cased borehole having a tubing string. However, this system describes a downhole toroid antenna for coupling electromagnetic energy in a waveguide TEM mode using the annulus between the casing and the tubing. This toroid antenna uses an electromagnetic wave coupling which requires a substantially nonconductive fluid (such as refined, heavy oil) in the annulus between the casing and the tubing and a toroidal cavity and wellhead insulators. Therefore, the method and system described in U.S. Pat. No. 4,839,644 is expensive, has problems with brine leakage into the casing, and is difficult to use as a scheme for downhole two-way communication.
Other downhole communication schemes such as mud pulse telemetry (U.S. Pat. Nos. 4,648,471; 5,887,657) have shown successful communication at low data rates but are of limited usefulness as a communication scheme where high data rates are required or it is undesirable to have complex, mud pulse telemetry equipment downhole. Still other downhole communication methods have been attempted, see U.S. Pat. Nos. 5,467,083; 4,739,325; 4,578,675; 5,883,516; and 4,468,665 as well as downhole permanent sensors and control systems: U.S. Pat. Nos. 5,730,219; 5,662,165; 4,972,704; 5,941,307; 5,934,371; 5,278,758; 5,134,285; 5,001,675; 5,730,219; 5,662,165.
It would, therefore, be a significant advance in the operation of petroleum wells if the tubing, casing, liners and other conductors installed in the well could be used for the communication and power conductors to control and operate devices and sensors downhole in a petroleum well.
Induction chokes have been used in connection with sensitive instrumentation to protect against surges and stray voltage. For example, most personal computers have some sort of choke incorporated into its AC power cord and video signal cable for such protection. Such protection chokes work well for their intended purpose, but do not operate to define a power or communication circuit.
All references cited herein are incorporated by reference to the maximum extent allowable by law. To the extent a reference may not be fully incorporated herein, it is incorporated by reference for background purposes and indicative of the knowledge of one of ordinary skill in the art.
The problems outlined above are largely solved and met by a petroleum well having one or more ferromagnetic chokes in accordance with the present invention. Broadly speaking, the petroleum well includes a cased wellbore having a tubing string positioned within and longitudinally extending within the casing. A controllable valve, sensor, or other device is coupled to the tubing. The valve sensor, or other device is powered and controlled from the surface. Communication signals and power are sent from the surface using the tubing, casing, or liner as the conductor. For example, AC current may be directed down the tubing to a point where the current encounters a choke. The voltage potential developed across the choke is used to power communication modems, valves, electronic devices and sensors near the choke.
In more detail, a surface computer includes a modem with an AC signal imparted to a conductive conduit, such as the tubing or casing. The AC signal develops a potential across a choke and a power supply creates DC voltage to power a connected controllable valve, sensor, or other device. Preferably, the casing or liner terminates at earth and is used as the ground return conductor, although an independent ground wire may be used. In a preferred embodiment, the powered device comprises a controllable valve that regulates passage of gas between the annulus and the interior of the tubing.
In enhanced forms, the petroleum well includes one or more sensors downhole which are preferably in contact with the downhole power and communications module and communicate with the surface computer. Such sensors as temperature, pressure, acoustic, valve position, flow rates, and differential pressure gauges are advantageously used in many situations. The sensors supply measurements to the modem for transmission to the surface or directly to a programmable interface controller operating a downhole device, such as controllable valve for controlling the gas flow through the valve.
Such ferromagnetic chokes are coupled to a conductor (tubing, casing, liner, etc.) to act as a series impedance to current flow. In one form, a ferromagnetic choke is placed around the tubing or casing downhole and the AC used for power and communication signal is imparted to the tubing, casing or liner near the surface. The downhole choke around the tubing, casing or liner develops a potential used to power and communicate with a controllable valve or sensor.
In another form, a surface computer is coupled via a surface master modem and the tubing or casing to a plurality of laterals, each having a downhole slave modem to operate a controllable valve in a lateral. The surface computer can receive measurements from a variety of sources, such as the downhole sensors, measurements of the oil output, and measurements of the fluid flow in each lateral. Using such measurements, the computer can compute an optimum position of each controllable valve, more particularly, the optimum amount or composition of fluid production from each lateral. Additional enhancements are possible, such as controlling the amount of compressed gas input into the well at the surface, controlling a surfactant injection system, and receiving production and operation measurements from a variety of other wells in the same field to optimize the production of the field.
Construction of such a petroleum well is designed to be as similar to conventional construction methodology as possible. That is, the well completion process comprises cementing a casing or liner within the borehole, placing production tubing within the casing or liner and generally concentric with such casing or liner, and placing a packer above the production zone to control fluid passage in the annulus between the tubing and the casing or liner. The completed well includes a choke concentric with the tubing, casing or liner. After cementing the well the casing is partially isolated from the earth. The tubing string passes through the casing and packer and communicates with the production zone. In the section of the tubing string near the choke, sensors or operating devices are coupled to the string. With such configuration a controllable gas lift valve or sensor pod may be directly permanently coupled to the tubing (i.e. “tubing conveyed”). Alternatively, a controllable gas lift valve or sensor pod may be inserted in a side pocket mandrel. A power and communications module uses the voltage potential developed across the choke to power the valve and sensors.
A sensor and communication pod can be inserted without the necessity of including a controllable gas lift valve or other control device. That is, an electronics module having pressure, temperature or acoustic sensors, power supply, and a modem is inserted into a side pocket mandrel for communication to the surface computer using the tubing and casing conductors. Alternatively, such electronics modules may be mounted directly on the tubing and not be configured to be wireline replaceable. If directly mounted to the tubing an electronic module or a device may only be replaced by pulling the entire tubing string. In another form, an insulated tubing section near the wellhead may be used to ensure electrical isolation.
In one broad aspect, the present invention relates to a current impedance device, particularly useful in petroleum wells, comprising a cylindrical choke of ferromagnetic material having an annular bore extending longitudinally therein and adapted for receiving petroleum well cylindrical conductor therein. Many modifications are, of course possible, with such ferromagnetic chokes being applicable to casing, tubing, liners, and headers and other conductors used downhole in a petroleum well.
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon referencing the accompanying drawings, in which:
Referring now to the drawings, wherein like reference numbers are used to designate like elements throughout the various views, several embodiments of the present invention are further described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated or simplified for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations of the present invention based on the following examples of possible embodiments of the present invention.
The terms “first end” and “second end” as used herein are defined generally to call out a side or portion of a piping structure, which may or may not encompass the most proximate locations, as well as intermediate locations along a called out side or portion of the piping structure. Similarly, in accordance with conventional terminology of oilfield practice, the descriptors “upper”, “lower”, “uphole” and “downhole” refer to distance along hole depth from the surface, which in deviated wells may or may not accord with absolute vertical placement measured with reference to the ground surface.
A piping structure can be one single pipe, a tubing string, a well casing, a pumping rod, a series of interconnected pipes or rods, a branch or lateral extension of a well, or a network of interconnected pipes. For the present invention, at least a portion of the piping structure needs to be electrically conductive, such electrically conductive portion may be the entire piping structure (e.g., steel pipes, copper pipes) or a longitudinal extending electrically conductive portion combined with a longitudinally extending non-conductive or partially resistive portion. In other words, an electrically conductive piping structure is one that provides an electrical conducting path from a first end where a power source is electrically connected to a second end where a device and/or electrical return is electrically connected. The piping structure will typically be conventional round metal tubing, but the cross-section geometry of the piping structure, or any portion thereof, can vary in shape (e.g., round, rectangular, square, oval) and size (e.g., length, diameter, wall thickness) along any portion of the piping structure.
In the first embodiment shown in
A second device terminal 52 is also electrically connected to the tubing 34, but at a location on the opposite side of the lower choke 32 relative to the electrical connection location for the first device terminal 51. As described further below with equations, a voltage potential exists across the choke 32 when a time-varying current flows through the tubing. Hence, the device 40 is electrically connected across the voltage potential on the tubing developed by the choke 32 when AC flows in the tubing 34, which provides current flow through the device 40.
Device 146 may consist of an electrically insulating joint hanger, or a choke in accordance with the present invention. While electrically insulating joint hangers provide true electrical isolation, they must sustain significant mechanical loads on insulating materials such as plastics or ceramics, and are therefore subject to damage from those loads. Chokes cannot provide complete isolation, but are able to sustain high mechanical loads since they are constructed such that all the load-bearing elements are composed of metal.
At least a portion of the well casing 36 is electrically conductive. The electrically conductive portion of the well casing 36 is electrically connected to the tubing 34 (e.g., via conductive fluid 82 and/or packer 56) and the source of current 38. Hence, the electrically conductive portion of the well casing 36 acts as part of an electrical return to complete the electrical circuit.
Where centralizers are used to control the position of the tubing 34 relative to the casing 36, such centralizers which are disposed between devices 30 and 32 must not be electrically conductive. Suitable centralizers are typically composed of molded or machined plastic.
Therefore, the electrical circuit is formed by the system of the first embodiment, wherein the time-varying current (e.g., AC) can flow from the power source 38 to the tubing 34, along the tubing 34 between the device 146 and the choke 32, through the device 40 to the tubing 34 below the lower choke 32, to the casing 36 via the packer 56 and/or the conductive fluid 82, and along the well casing 36 to the source 38 to complete the electrical circuit. Thus, the downhole device 40 can receive power, as well as send/receive communication signals, using the tubing 34 between the upper and lower devices 146, 32 as one of the primary conductors and as a power and/or communications path.
In the application of the first embodiment shown in
A gas input throttle 74 is employed to permit the input of compressed gas into the tubing 34 via one or more valves contained within pod 40 for lifting oil during production. Schematically illustrated is a computer system and power source 38 at the surface 64 with power and communication feeds 44 passing through electrically isolating pressure seal 76 and using return connection 78, which is electrically connected to the casing 36. The degree of opening of gas lift valve may be controlled by means of setpoint commands sent by communication from the surface modem to the downhole modem and interpreted by a downhole control interface for the motor of the gas lift valve. Sensor readings from the downhole pod may either be processed locally within the pod to provide autonomous control, or the sensor readings may be conveyed to the surface by means of the communications between the downhole and surface modems, for analysis at the surface.
The choke 32 is unpowered and made from a material having a high magnetic permeability (e.g., a relative permeability of 1000 to 150,000), such as a ferromagnetic metal alloy or a ferrite. The choke 32 is electrically insulated from the tubing 34 and acts to create a reactive impedance to AC flow in the tubing. In the case where the upper device 146 is a choke (rather than an electrically insulating joint), its action and construction is essentially the same as the lower choke 32. The choke 32 (and 146 in the case where it is a choke) are mounted concentric and external to the tubing 34 and are typically coated with shrink-wrap plastic to provide electrical insulation, and may additionally be enclosed within an epoxy or other structurally equivalent shell (not shown) to withstand rough handling and corrosive conditions. As described in the mathematical analysis below, the size and material of chokes can be chosen to achieve a desired series impedance value.
Referring still to
Referring still to
It is seen from
Choke sub-sections 134 are formed by winding about 60 sheet laminations of a high-permeability ferromagnetic alloy such as Permalloy (Permalloy is a registered Trademark, of Western Electric Company). Permalloy is a nickel/iron alloy with a nickel content in the range 35% to 90% and is available as a commodity material from many commercial sources. A suitable alloy is composed of 86% nickel/14% iron, and the laminations are 0.014 inches thick and 2.35 inches wide such that the final dimensions of each choke section are 3.6 inches internal diameter, 5.45 inches external diameter, and 2.35 inches in the direction of the choke axis 60. The laminating material is coated with a non-conductive material such that adjacent laminations are electrically isolated from each other, as in standard transformer construction practice. Fifteen such choke sections are stacked to form a total choke assembly suitable for usual power frequencies, 50 or 60 Hertz. At power frequencies up to a few hundred Hertz, the laminated ferromagnetic alloy construction can be used for the choke sections, as in standard transformer design practice, and as described above. Lamination is required to reduce eddy current losses which would otherwise degrade the effectiveness of the choke. For material with absolute magnetic permeability of 50,000 operating at 60 Hertz the required lamination thickness for 2 skin depths is 0.8-millimeters (0.031 inches), which is realistic and practical.
Between each choke section is a polytetrafluoroethylene (PTFE) washer 136 with internal diameter 3.6 inches, external diameter 5.45 inches, and thickness 0.030 inches. After all the chokes are threaded onto the tubing, the entire section of chokes is covered with PTFE heatshrink tubing 138 having 0.020 inches wall thickness. The stainless steel rod 51 is 0.125 inches diameter covered with polyethylene (PE) heat-shrink tubing and extends along the length of the completed choke assembly. It is attached to the upper welding collar 50 and passes through holes in the centralizers 114. Its lower end is electrically connected to the input of the electrical pod which is below the choke assembly.
The impedance offered by the choke is a critical implementation issue, since this determines what proportion of total power supplied to the pipe will be lost to leakage through the choke, and what proportion will be available to power and communicate with the devices installed in the isolated section of the pipe. Since the impedance presented by an inductor increases with frequency, the AC power frequency is used in both the theoretical analysis and the testing of alternative choke configurations, as this is normally equal to or lower than the communication frequencies.
The defining variables and a self-consistent set of physical units are:
L=length of choke, meters;
a=choke inner radius, meters;
b=choke outer radius, meters;
r=distance from choke axis, meters;
I=r.m.s. net current through choked section, Amperes;
ω angular frequency of leakage current, radians per second;
By definition, (ω=2πf where f=frequency in Hertz.
At a distance r from the current I, the r.m.s. free space magnetic field H, in Henries per meter, is given by:
The field H is circularly symmetric about the choke axis, and can be visualized as magnetic lines of force forming circles around that axis.
For a point within the choke material, the r.m.s. magnetic field B, in Teslas, is given by:
The r.m.s. magnetic flux F contained within the choke body, in Webers, is given by:
where S is the cross-sectional area of the choke in square meters as shown in
where ln is the natural logarithm function.
The voltage generated by the flux F, in Volts, is given by:
Note that the back-e.m.f. (V) is directly proportional to the length (L) of the choke for constant values of (a) and (b), the choke element internal and external radii. Thus by altering the length of the choke, any desired back-e.m.f. can be generated for a given current.
Inserting representative values:
μ=50,000×(4π×10−7), L=1 meter, I=10 Amperes, f=60 Hertz,
a=0.045 meters (3.6 inch inner diameter), b=0.068 meters (5.45 inch external diameter):
then the back-e.m.f. developed V=2.6 Volts
showing that such a choke is effective in developing the required downhole voltage, and does so when realistic and safe currents and voltages are impressed upon the tubing and transmitted from the well head to downhole equipment.
Each device 40 comprises a control module 110, sensors 120, a modem 122, an electric motor 124, and an electrically controllable valve 126. The control module 110 receives power and/or communications from the tubing 34, which it uses to provide power, control, and communications for the sensors 120, modem 122, and electric motor 124. The control module 110 can contain various logic structures for closed loop control of the valve 126 based on measurements taken by the sensors 120. In this example, there is a pressure sensor, a temperature sensor, and a flow sensor. However, other types of sensors 120 can also be used or substituted (e.g., acoustic sensor, chemical composition sensor). The modem 122 in the device 40 can send data from the sensors 120 to the computer system at the surface 64. Also, the modem 122 can receive control signals from the computer system via the modem in the source 38. The control module 110 provides power and control for the electric motor 124, which is capable of operating with low current. The electric motor 124 is used to open, close, or adjust the valve 126. Each control module 110 for each lateral branch 88 can be separately addressable, each sensor 120 can be separately monitored, and each valve 126 can be independently operated. Hence, using a system incorporating the third embodiment, each valve 126 in each lateral branch 88 can be electrically controlled to manage the fluid flow from each lateral.
It will be clear to those skilled in the art that the effect of the chokes in offering an impedance to AC current flow can be exploited in a variety of ways as alternative embodiments for the provision and distribution of power along the metal structures of wells.
A combination of the configurations of
The ability to reconfigure power routing to multiple downhole pods as shown in
There exists a constraint on this zone power selection method. Pods lower in the well must respond to lower applied AC frequency, and pods higher in the well must respond to higher AC frequency, so that the AC impeding effect of the upper chokes does not significantly prevent power from flowing to the lower chokes.
In the choke design analysis previously described with reference to
The potential developed on the casing across the choke 32 is connected by electrical conductors 51 and 52 to power and communicate with an instrument pod 40 located external to the casing. Chokes 30, 32, and the instrument pod 40, are set in the well with the casing and before the cement 70 is injected. As in the previous embodiments the instrument pod 40 may provide bidirectional communication through a modem to return data to the surface from sensors to measure conditions such as formation pressure, temperature, acoustic signals etc connected to pod 40, and to accept control commands from the surface.
Many of the examples described thus far have focused on gas lift petroleum wells. However, a rod pumping artificial lift or “sucker rod” oil well may also incorporate the present invention.
Referring still to
At depth 203 in the well, the production tubing 234 is furnished with a choke 232 and an electrical pod 210. These function as described in reference to FIGS. 1 and 2, with the return connection from the downhole equipment being effected by the downhole ground connection 72.
Even though many of the examples discussed herein are applications of the present invention in petroleum wells, the present invention also can be applied to other types of wells, including but not limited to: water wells and natural gas wells.
Also in a possible embodiment (not shown) of the present invention, the piping structures of two adjacent wells can be used to form a current loop for the electrical circuit. For example, a second end of a piping structure of a first well may be electrically connected (e.g., via a wire, conductive fluid, and/or the earth) to a second end of a piping structure of a second well adjacent to the first well, and a first end of the piping structure of the first well is electrically connected to a first terminal of a power source and a first end of the piping structure of the second well is electrically connected to a second terminal of the source, such that the electrical circuit is formed by using the piping structures of both wells. Hence, one of the piping structures will act as an electrical return. In another possible embodiment (not shown), two piping structures of a same well (e.g., two adjacent lateral branches) can be used to form a current loop for an electrical circuit. For example, the piping structure can be a first lateral branch and the electrical return can be a second lateral branch.
One skilled in the art will see that the present invention can be applied in many areas where there is a need to provide power and/or communication within a borehole, well, or any other area that is difficult to access. As discussed above, a production tubing string, as used in oil fields for withdrawing oil from a reservoir, is an example of a well with limited access downhole. Another example is the use of the present invention to provide power and/or communications to a device within a borehole of a machine part, where access within the borehole is limited. For example, when looking for cracks in a steam turbine using nondestructive testing techniques (e.g., ultrasonics, eddy current), there is often a need to provide power and communications to a sensor deep within a borehole of the steam turbine rotor that may be three to six inches in diameter and thirty feet long. The piping structure can comprise a rod or tube that physically supports the sensor, and the electrical return can comprise the machine part being inspected. Hence, the use of the present invention can provide a system and method of providing power and communications to a sensor deep within the borehole where access is limited.
Also, one skilled in the art will see that the present invention can be applied in many areas where there is an already existing conductive piping structure and a need to route power and/or communications in a same or similar path as the piping structure. A water sprinkler system or network in a building for extinguishing fires is an example of a piping structure that may be already existing and having a same or similar path as that desired for routing power and/or communications. In such case another piping structure or another portion of the same piping structure may be used as the electrical return. The steel structure of a building may be used as an electrically conductive structure and/or electrical return for transmitting power and/or communications in accordance with the present invention. The steel reinforcing bar in a concrete dam or a street pavement may be used as an electrically conductive structure and/or electrical return for transmitting power and/or communications in accordance with the present invention. The transmission lines and network of piping between wells or across large stretches of land may be used as a piping structure and/or electrical return for transmitting power and/or communications in accordance with the present invention. Surface refinery production pipe networks may be used as a piping structure and/or electrical return for transmitting power and/or communications in accordance with the present invention. Thus, there are numerous applications of the present invention in many different areas or fields of use.
It will be appreciated by those skilled in the art having the benefit of this disclosure that this invention provides a system that uses at least one unpowered induction choke to form an electrical circuit in a piping structure. It will also be appreciated by those skilled in the art having the benefit of this disclosure that this invention provides a system for providing power and/or communications to a device downhole in a borehole of a well using an electrical circuit formed in a piping structure by using at least one unpowered induction choke. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to limit the invention to the particular forms and examples disclosed. On the contrary, the invention includes any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope of this invention, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.