Technical field
[0001] This invention relates to telemetry systems for use with installations in oil and
gas wells or the like. In particular, the invention relates to wireless telemetry
systems for transmitting data and control signals between surface installations and
downhole tools.
Background art
[0002] Downhole testing is traditionally performed in a "blind fashion": downhole tools
and sensors are deployed in a well at the end of a tubing string for several days
or weeks after which they are retrieved at surface. During the downhole testing operations,
the sensors may record measurements that will be used for interpretation once retrieved
at surface. It is only after the downhole testing tubing string is retrieved that
the operators will know whether the data are sufficient and not corrupted. Similarly
when operating some of the downhole testing tools from surface, such as tester valves,
circulating valves, packer, samplers or perforating charges, the operators do not
obtain a direct feedback from the downhole tools.
[0003] In this type of downhole testing operations, the operator can greatly benefit from
having a two-way communication between surface and downhole. However, it can be difficult
to provide such communication using a cable since inside the tubing string it limits
the flow diameter and requires complex structures to pass the cable from the inside
to the outside of the tubing. A cable inside the tubing is also an additional complexity
in case of emergency disconnect for an offshore platform. Space outside the tubing
is limited and cable can easily be damaged. Therefore a wireless telemetry system
is preferred.
[0005] In
EP0550521, an acoustic telemetry system is used to pass data across an obstruction in the tubing,
such as a valve. The data is then stored for retrieval by a wireline tool passed inside
the tubing from the surface. It is also proposed to retransmit the signal as an acoustic
signal.
EP1882811 discloses an acoustic transducer structure that can be used as a repeater along the
tubing.
[0006] It is an object of this invention to provide a system that combines different types
of telemetry so as to take advantage of the best features of the different types of
telemetry while providing alternatives to avoid the limitations of any of them.
Disclosure of the invention
[0007] A first aspect of this invention provides apparatus for transmitting data in a borehole
between a downhole tool installation including one or more tools (for example downhole
testing tools) and a surface installation, wherein the downhole tool installation
is connected to the surface installation by means of a tubular conduit (such as a
drill string or production tubing), the apparatus comprising
- an acoustic modem associated with each tool, the modem acting to convert tool signals
such as electrical tool signals into acoustic signals;
and
- a hub forming part of the downhole installation to which the tools and tubular conduit
are connected and comprising an acoustic receiver and an electromagnetic transmitter;
wherein the acoustic modems operate to generate acoustic signals in the installation
representative of the tool signals, the acoustic tool signal passing along the downhole
installation to be received at the acoustic receiver of the hub, the received acoustic
signals being used to operate the electromagnetic transmitter to transmit electromagnetic
signals to the surface for reception at the surface installation.
[0008] Preferably, the hub further comprises an acoustic transmitter which is operable to
transmit the acoustic signals received by the hub to the surface installation via
the tubular conduit.
[0009] One or more acoustic repeaters can be disposed along the tubular conduit and operated
to retransmit the acoustic signal received from the hub.
[0010] At least one tool can be located below and/or above the hub.
[0011] The downhole installation typically comprises at least one packer to isolate a zone
of the borehole below the hub. In one embodiment multiple packers are arranged to
isolate multiple zones of the well below the hub. In this case, the downhole installation
can comprise separate tools in each zone.
[0012] The hub can further comprise an electromagnetic receiver for receiving electromagnetic
signals from the surface installation, and an acoustic transmitter for transmitting
acoustic signals derived from the received electromagnetic signals.
[0013] A second aspect of the invention provides a method of communicating between one or
more tools comprising a downhole installation and a surface installation, wherein
the downhole installation and surface installation are connected by means of a tubular
conduit, the method comprising:
- using signals produced by the tools to generate acoustic signals which pass along
the downhole installation to a hub;
- receiving the acoustic signals at the hub; and
- using the received acoustic signals to generate electromagnetic signals that pass
from the hub to the surface location.
[0014] The tool signals can be preferably electrical signals or digital signals.
[0015] In one embodiment, the method further comprises generating acoustic signals at the
hub which pass along the tubular conduit to the surface installation. In this case,
the method can also include receiving the acoustic signals and retransmitting them
at multiple locations along the tubular conduit.
[0016] One preferred embodiment further comprised transmitting electromagnetic signals from
the surface installation to the hub and converting these signals into acoustic signals
for transmission to the tools in the installation.
[0017] Further aspects of the invention will be apparent from the following description.
Brief description of the drawings
[0018]
Figure 1 shows a schematic view of an acoustic telemetry system for use in the invention;
Figure 2 shows a modem as used in the embodiment of Figure 1;
Figure 3 shows a variant of the embodiment of Figure 1;
Figure 4 shows a hybrid telemetry system according to an embodiment of the invention;
Figure 5 shows a schematic view of a modem;
Figure 6 shows a detailed view of a downhole installation incorporating the modem
of Figure 5;
Figure 7 shows one embodiment of mounting the modem in downhole equipment;
Figure 8 shows one embodiment of mounting a repeater modem on drill pipe;
Figure 9 shows a dedicated modem sub for mounting in drill pipe; and
Figures 10, 11 and 12 illustrate applications of a hybrid telemetry system according
to the invention.
Mode(s) for carrying out the invention
[0019] This invention is particularly applicable to testing installations such as are used
in oil and gas wells or the like. Figure 1 shows a schematic view of such a system.
Once the well has been drilled, the drilling apparatus is removed from the well and
tests can be performed to determine the properties of the formation though which the
well has been drilled. In the example of Figure 1, the well 10 has been lined with
a steel casing 12 (cased hole) in the conventional manner, although similar systems
can be used in unlined (open hole) environments. In order to test the formations,
it is necessary to place testing apparatus in the well close to the regions to be
tested, to be able to isolate sections or intervals of the well, and to convey fluids
from the regions of interest to the surface. This is commonly done using a jointed
tubular drill pipe 14 which extends from the well-head equipment 16 at the surface
(or sea bed in subsea environments) down inside the well to the zone of interest.
The well-head equipment 16 can include blow-out preventers and connections for fluid,
power and data communication.
[0020] A packer 18 is positioned on the drill pipe 14 and can be actuated to seal the borehole
around the drill pipe 14 at the region of interest. Various pieces of downhole test
equipment 20 are connected to the drill pipe 14 above or below the packer 18. These
can include:
- Further packers
- Tester valves
- Circulation valves
- Downhole chokes
- Firing heads
- TCP (tubing conveyed perforator) gun drop subs
- Samplers
- Pressure gauges
- Downhole flow meters
- Downhole fluid analysers
- Etc.
[0021] In the embodiment of Figure 1, a sampler 22 is located below the packer 18 and a
tester valve 24 located above the packer 18. The downhole equipment 20 is connected
to a downhole modem 26 which is mounted in a gauge carrier 28 positioned between the
sampler 22 and tester valve 24. The modem 26 operates to allow electrical signals
from the equipment 20 to be converted into acoustic signals for transmission to the
surface, and to convert acoustic tool control signals from the surface into electrical
signals for operating the equipment downhole.
[0022] Figure 2 shows the modem 26 in more detail. The modem comprises a housing 30 supporting
a piezo electric actuator or stack 32 which can be driven to create an acoustic signal
in the drill pipe 14 when the modem 26 is mounted in the gauge carrier 28. The modem
26 can also include an accelerometer 34 or monitoring piezo sensor 35 for receiving
acoustic signals. Where the modem is only required to act as a receiver, the piezo
actuator 32 may be omitted. Transmitter electronics 36 and receiver electronics 38
are also located in the housing and power is provided by means of a battery, such
as a lithium rechargeable battery 40. Other types of power supply may be used also.
[0023] The transmitter electronics 36 are arranged to receive an electrical output signal
from a sensor 42, for example from the downhole equipment 20 provided from an electrical
or electro/mechanical interface. Such signals are typically digital signals which
can be provided to a micro-controller 43 which uses the signal to derive a modulation
to be applied to a base band signal in one of a number of known ways FSK, PSK, QPSK,
QAM. This modulation is applied via a D/A converter 44 which outputs an analogue signal
(typically a voltage signal) to a signal conditioner 46. The conditioner operates
to modify the signal to match the characteristics of the piezo actuator 32. The analogue
signals are stacked and applied as a drive signal to the piezo stack so as to generate
an acoustic signal in the material of the drill pipe 14. The acoustic signal comprises
a carrier signal with an applied modulation to provide a digital signal that passes
along the drill pipe as a longitudinal and/or flexural wave. The acoustic signal typically
has a frequency in the range 1-10kHz, preferably in the range 3-6kHz, and is configured
to pass data at a rate of about 1 bps to about 1000 bps, preferably from about 10
to about 100 bps,and more preferably from over about 80 bps. The data rate is dependent
upon the conditions such as the noise and the distance between the repeaters. A preferred
embodiment of the invention is directed to a combination of a short hop acoustic telemetry
system for transmitting data between a hub located above the main packer and a plurality
of downhole tools and valves below and/or above said packer. Then the data and/or
control signals can be transmitted from the hub to a surface module either via a plurality
of repeaters as acoustic signals or by converting into electromagnetic signals and
transmitting straight to the top. The combination of a short hop acoustic with a plurality
of repeaters and/or the use of the electromagnetic waves allows an improved data rate
over existing systems. The system may be designed to transmit data as high as 1000
bps. Other advantages of the present invention system exist.
[0024] The receiver electronics are arranged to receive the acoustic signal passing along
the drill pipe 14 and convert it to an electric signal. The acoustic signal passing
along the pipe excites the accelerometer 34 or monitor stack 35 so as to generate
an electric output signal (voltage). This signal is essentially an analogue signal
carrying digital information. The analogue signal is applied to a filter 48 and then
to a A/D converter 50 to provide a digital signal which can be applied to a microcontroller
52. The micro controller 52 which implements signal processing. The type of processing
applied to the signal depends on whether it is a data signal or a command signal.
The signal is then passed on to an actuator 54.
[0025] The modem 26 can therefore operate to transmit acoustic data signals from the sensors
in the downhole equipment 20 along the drill pipe 14. In this case, the electrical
signals from the equipment 20 are applied to the transmitter electronics 36 (described
above) which operate to generate the acoustic signal. The modem 26 can also operate
to receive acoustic signals control signals to be applied to the downhole equipment
20. In this case, the acoustic signals are detected and applied to the receiver electronics
38 (described above) which operate to generate the electric control signal that is
applied to the equipment 20.
[0026] In order to support acoustic signal transmission along the drill pipe 14 between
the downhole location and the surface, a series of repeater modems 56a, 56b, etc.
are positioned along the drill pipe 14. These repeater modems 56 operate to receive
an acoustic signal generated in the drill pipe by a preceding modem and to amplify
and retransmit the signal for further propagation along the drill string. The number
and spacing of the repeater modems 56 will depend on the particular installation selected,
for example on the distance that the signal must travel. A typical minimum spacing
to the modems is 500m in order to accommodate all possible testing tool configurations.
When acting as a repeater, the acoustic signal is received and processed by the receiver
electronics 38 and the output signal is provided to the microcontroller of the transmitter
electronics 36 and used to drive the piezo stack in the manner described above. Thus
an acoustic signal can be passed between the surface and the downhole location in
a series of short hops.
[0027] The role of a repeater is to detect an incoming signal, to decode it, to interpret
it and to subsequently rebroadcast it if required. In some implementations, the repeater
does not decode the signal but merely amplifies the signal (and the noise). In this
case the repeater is acting as a simple signal booster. However, this is not the preferred
implementation selected for wireless telemetry systems of the invention.
[0028] Repeaters are positioned along the tubing/piping string. A repeater will either listen
continuously for any incoming signal or may listen from time to time.
[0029] The acoustic wireless signals, conveying commands or messages, propagate in the medium
(the drill pipe) in an omni-directional fashion, that is to say up and down. It is
not necessary for the detector to detect whether the physical wireless signal is coming
from another repeater above or below. The direction of the message is embedded in
the message itself. Each message contains several network addresses: the address of
the transmitter (last and/or first transmitter) and the address of the destination
modem at least. Based on the addresses embedded in the messages, the repeater will
interpret the message and construct a new message with updated information regarding
the transmitter and destination addresses. Messages will be transmitted from repeaters
to repeaters and slightly modified to include new network addresses.
[0030] If the repeater includes an array of sensors, and if the channel is non reverberant,
then it is possible to determine the direction of the incoming signal, using classical
array processing (similar to that found in borehole seismics, acoustic tools, phased
array radars or ultrasonic, etc). This applies for a propagating wave (acoustic or
high frequency electromagnetic, for example), but not for a diffusive wave such as
a low frequency electromagnetic wave.
[0031] A surface modem 58 is provided at the well head 16 which provides a connection between
the drill pipe 14 and a data cable or wireless connection 60 to a control system 62
that can receive data from the downhole equipment 20 and provide control signals for
its operation.
[0032] In the embodiment of Figure 1, the acoustic telemetry system is used to provide communication
between the surface and the downhole location. Figure 3 shows another embodiment in
which acoustic telemetry is used for communication between tools in multi-zone testing.
In this case, two zones A, B of the well are isolated by means of packers 18a, 18b.
Test equipment 20a, 20b is located in each isolated zone A, B, corresponding modems
26a, 26b being provided in each case. Operation of the modems 26a, 26b allows the
equipment in each zone to communicate with each other as well as allowing communication
from the surface with control and data signals in the manner described above.
[0033] Figure 4 shows an embodiment of the invention with a hybrid telemetry system. The
testing installation shown in Figure 4 comprises a lower section 64 which corresponds
to that described above in relation to Figures 1 and 3. As before, downhole equipment
66 and packer(s) 68 are provided with acoustic modems 70. However, in this case, the
uppermost modem 72 differs in that signals are converted between acoustic and electromagnetic
formats. Figure 5 shows a schematic of the modem 72. Acoustic transmitter and receiver
electronics 74, 76 correspond essentially to those described above in relation to
Figure 2, receiving and emitting acoustic signals via piezo stacks (or accelerometers).
Electromagnetic (EM) receiver and transmitter electronics 78, 80 are also provided,
each having an associated microcontroller 82, 84. A typical EM signal will be a digital
signal at about 1 Hz. This signal is received by the receiver electronics 78 and passed
to an associated microcontroller 82. Data from the microcontroller 82 can be passed
to the acoustic receiver microcontroller 86 and on to the acoustic transmitter microcontroller
88 where it is used to drive the acoustic transmitter signal in the manner described
above. Likewise, the acoustic signal received at the receiver microcontroller 86 can
also be passed to the EM receiver microcontroller 82 and then on to the EM transmitter
microcontroller 84 where it is used to drive an EM transmitter antenna to create a
1 Hz digital EM signal that can be transmitted along the well to the surface. A corresponding
EM transceiver (not shown) is provided at the surface for connection to the control
system.
[0034] Figure 6 shows a more detailed view of a downhole installation in which the modem
72 forms part of a downhole hub 90 that can be used to provide short hop acoustic
telemetry X with the various downhole tools 20 (e.g test and circulation valves (i),
flowmeter (ii), fluid analyser (iii) and packer (iv), and other tools below the packer
(v)), and long hop EM telemetry Y to the surface.
[0035] Figure 7 shows the manner in which a modem can be mounted in downhole equipment.
In the case shown, the modem 92 is located in a common housing 94 with a pressure
gauge 96, although other housings and equipment can be used. The housing 94 is positioned
in a recess 97 on the outside of a section of drill pipe 98 provided for such equipment
and commonly known as a gauge carrier. By securely locating the housing 94 in the
gauge carrier 97, the acoustic signal can be coupled to the drill pipe 98. Typically,
each piece of downhole equipment will have its own modem for providing the short hop
acoustic signals, either for transmission via the hub and long hop EM telemetry, or
by long hop acoustic telemetry using repeater modems. The modem is hard wired into
the sensors and actuators of the equipment so as to be able to receive data and provide
control signals. For example, where the downhole equipment comprises an operable device
such as a packer, valve or choke, or a perforating gun firing head, the modem will
be used to provide signals to set/unset, open/close or fire as appropriate. Sampling
tools can be instructed to activate, pump out, etc. and sensors such as pressure and
flow meters can transmit recorded data to the surface. In most cases, data will be
recorded in tool memory and then transmitted to the surface in batches. Likewise tool
settings can be stored in the tool memory and activated using the acoustic telemetry
signal.
[0036] Figure 8 shows one embodiment for mounting the repeater modem on drill pipe. In this
case, the modem 100 is provided in an elongate housing 102 which is secured to the
outside of the drill pipe 104 by means of clamps 106. Each modem is a stand-alone
installation, the drill pipe providing both the physical support and signal path.
[0037] Figure 9 shows an alternative embodiment for mounting the repeater modem. In this
case, the modem 108 is mounted in an external recess 110 of a dedicated tubular sub
112 that can be installed in the drill string between adjacent sections of drill pipe.
Multiple modems can be mounted on the sub for redundancy.
[0038] The preferred embodiment of the invention comprises a two-way wireless communication
system between downhole and surface, combining different modes of electromagnetic
and acoustic wave propagations. It may also include a wired communication locally,
for example in the case of offshore operations. The system takes advantage of the
different technologies and combines them into a hybrid system, as presented in Figure
4.
[0039] The purpose of combining the different types of telemetry is to take advantage of
the best features of the different types of telemetry without having the limitations
of any of them. The preferred applications for embodiments of this invention are for
single zone and multi-zone well testing in land and offshore environments. In the
case of the deep and ultra-deep offshore environments, the communication link has
to be established between the floating platform (not shown) and the downhole equipment
66 above and below the packer 68. The distance between the rig floor (on the platform)
and the downhole tools can be considerable, with up to 3km of sea water and 6km of
formation/well depth. There is a need to jump via a 'Long Hop' from the rig floor
to the top of the downhole equipment 66 but afterwards it is necessary to communicate
locally between the tools 66 (sensors and actuators) via a 'Short Hop' within a zone
or across several zones. The Short Hop is used as a communication means that supports
distributed communication between the Long Hop system and the individual tools that
constitute the downhole equipment 66, as well as between some of these tools within
the downhole installation. The Short Hop communication supports:
- Measurement data:
○ Gauge pressure, temperature
○ Downhole flowrates
○ Fluid properties
○ etc
- Downhole tool status and activation commands:
○ IRDV
○ Samplers (multiple)
○ Firing Heads (multiple)
○ Packer activation
○ Other downhole tools (tubing tester, circulating valve, reversing valve etc)
○ etc
[0040] All telemetry channels, being wireless or not, have limitations from a bandwidth,
deployment, cost or reliability point of view. The objective of the invention is to
combine the various technology benefits. These are summarized in Figure 10.
[0041] At low frequency (∼1 Hz), electromagnetic waves 120 propagate very far with little
attenuation through the formation 122. The higher the formation resistivity, the longer
the wireless communication range. The main advantages of electromagnetic wave communication
relate to the long communication range, the independence of the flow conditions and
the tubing string configuration 124. The main drawbacks of the electromagnetic wave
communication are related to the required power and associated footprint.
[0042] Acoustic wave propagation 126 along the tubing string 124 can be made in such a way
that each element of the system is small and power effective by using high frequency
sonic wave (1 to 10kHz). In this case, the main advantages of this type of acoustic
wave communication relate to the small footprint and the medium date rate of the wireless
communication. The main drawbacks of the acoustic wave communication are related to
the impact of noise induced by production flows, the unpredictability of the communication
carrier frequency and the requirements for continuity in the pipe structure.
[0043] Electrical or optical cable technology 128 can provide the largest bandwidth and
the most predictable communication channel. The energy requirements for digital communication
are also limited with electrical or optical cable, compared to wireless telemetry
systems. It is however costly and difficult to deploy cable over several kilometers
in a well (rig time, clamps, subsea tree) especially in the case of a temporary well
installation, such as a well test.
[0044] In the case of deep-offshore single zone or multi-zone well testing, an appropriate
topology for the hybrid communication system is to use a cable 128 (optical or electrical)
from the rigfloor to the seabed, an electromagnetic wireless communication 120 from
the seabed to the top of the downhole equipment and an acoustic communication 126
for the local bus communication.
[0045] Another way to combine the telemetry technologies is to place the telemetry channels
in parallel to improve the system reliability through redundancy. Figures 11 and 12
represent two cases where two or three communication channels are placed in parallel.
In Figure 11, both electromagnetic 120 and acoustic 126 wireless communication is
used to the wellhead; and a cable 128 leads from the wellhead to the rig floor (not
shown) In such configurations, common nodes 130 to the different communication channels
can be used. Such nodes have essentially the similar functions to the hub described
above in relation to Figure 6. In Figure 12, electromagnetic 120 and acoustic 126
wireless, and cable 128 are all provided down to the downhole location, the acoustic
wireless signal being used between the downhole tools. The selection of the particular
communication channel used can be done at surface or downhole or at any common mode
between the channels. Multiple paths exist for commands to go from surface to downhole
and for data and status to go from downhole to surface. In the event of communication
loss on one segment of one channel, an alternate path can be used between two common
nodes.
[0046] A particularly preferred embodiment of the invention relates to multi-zone testing
(see Figure 4). In this case, the well is isolated into separate zones by packers
68, and one or more testing tools are located in each zone. A modem is located in
each zone and operates to send data to the hub 72 located above the uppermost packer.
In this case, the tools in each zone operate either independently or in synchronisation.
The signals from each zone are then transmitted to the hub for forwarding to the surface
via any of the mechanisms discussed above. Likewise, control signals from the surface
can be sent down via these mechanisms and forwarded to the tools in each zone so as
to operate them either independently or in concert.
[0047] Further changes within the scope of the invention are also possible.
1. Apparatus for transmitting data in a borehole between a downhole tool installation
including one or more tools and a surface installation, wherein the downhole tool
installation is connected to the surface installation by means of a tubular conduit,
the apparatus comprising
- an acoustic modem associated with each tool, the modem acting to convert electrical
tool signals into acoustic signals; and
- a hub forming part of the downhole installation to which the tools and tubular conduit
are connected and comprising an acoustic receiver and an electromagnetic transmitter;
wherein the acoustic modems operate to generate acoustic signals in the installation
representative of the electrical tool signals, the acoustic tool signal passing along
the downhole installation to be received at the acoustic receiver of the hub, the
received acoustic signals being used to operate the electromagnetic transmitter to
transmit electromagnetic signals to the surface for reception at the surface installation.
2. Apparatus as claimed in claim 1, wherein the hub further comprises an acoustic transmitter
which is operable to transmit the acoustic signals received by the hub to the surface
installation via the tubular conduit.
3. Apparatus as claimed in claim 2, further comprising one or more acoustic repeaters
disposed along the tubular conduit and operable to retransmit the acoustic signal
received from the hub.
4. Apparatus as claimed in claim 1, 2 or 3, wherein at least one tool is located below
the hub.
5. Apparatus as claimed in any preceding claim, wherein at least one tool is located
above the hub.
6. Apparatus as claimed in any preceding claim, wherein the downhole installation comprises
at least one packer to isolate a zone of the borehole below the hub.
7. Apparatus as claimed in claim 6, comprising multiple packers arranged to isolate multiple
zones of the well below the hub.
8. Apparatus as claimed in claim 7, wherein the downhole installation comprises separate
tools in each zone.
9. Apparatus as claimed in any preceding claim, wherein the hub further comprises and
electromagnetic receiver for receiving electromagnetic signals from the surface installation,
and an acoustic transmitter for transmitting acoustic signals derived from the received
electromagnetic signals.
10. A method of communicating between one or more tools comprising a downhole installation
and a surface installation, wherein the downhole installation and surface installation
are connected by means of a tubular conduit, the method comprising:
- using electrical signal produced by the tools to generate acoustic signals which
pass along the downhole installation to a hub;
- receiving the acoustic signals at the hub; and
- using the received acoustic signals to generate electromagnetic signals that pass
from the hub to the surface location.
11. A method as claimed in claim 1, further comprising generating acoustic signals at
the hub which pass along the tubular conduit to the surface installation.
12. A method as claimed in claim 11, further comprising receiving the acoustic signals
and retransmitting them at multiple locations along the tubular conduit.
13. A method as claimed in claim 10, 11 or 12, further comprising transmitting electromagnetic
signals from the surface installation to the hub and converting these signals into
acoustic signals for transmission to the tools in the installation.
14. A method of testing a well, comprising:
- locating testing tools in a borehole in a number of zones to be tested;
- isolating the zones from each other and the rest of the well;
- operating the testing tools in each zone; and
- transmitting data from the testing tools in each zone to a surface installation
by means of a method according to any of claims 10-13.