Surface communication system for communication with downhole wireless modem prior to deployment

Abstract

 An apparatus is made of a surface communication system for communicating wirelessly with a first wireless modem mounted within a section of tubing, and configured to communicate wirelessly with a second wireless modem through a tubing including the section of tubing and within a well at a distance in excess of 500 feet , comprising: a transceiver assembly adapted to be positioned on the section of tubing and in close proximity with the first wireless modem; transmitter electronics configured to provide low power signals to the transceiver assembly to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and receiver electronics configured to receive and interpret high power signals from the transceiver assembly.

Description

TECHNICAL FIELD

[0001] The invention relates generally to a wireless communication system for communication with a wireless modem configured for use in a wellbore prior to deployment. More particularly, but not by way of limitation, the present invention relates to a wireless communication system for communication with a wireless modem configured for use in a wellbore after the wireless modem has been mounted within a housing but prior to deployment in the wellbore. The communication can be, but is not limited to testing and/or controlling the state of the wireless modem and/or a downhole tool in communication with the wireless modem.

BACKGROUND ART

[0002] After a wellbore has been drilled, it is desired to perform tests of formations surrounding the wellbore. Logging tests may be performed, and samples of formation fluids may be collected for chemical and physical analyses. The information collected from logging tests and analyses of properties of sampled fluids may be used to plan and develop wellbores and for determining their viability and potential performance.

[0003] Many types of downhole tools are used in the testing and production of hydrocarbon wells. Exemplary downhole tools include flow control valves, packers, pressure gauges, and fluid samplers. For example, fluid sampling is often conducted during drill stem testing of hydrocarbon wells. During a well test, many types of downhole tools such as flow control valves, packers, pressure gauges, and fluid samplers are lowered into the well on a pipe string. Once the packer has been set and a cushion fluid having an appropriate density is displaced in the well above the flow control or tester valve, the valve is opened and hydrocarbons are allowed to flow to the surface where the fluids are separated and disposed of during the test. At various times during the test, the downhole tester valve is closed and the downhole pressure is allowed to build up to its original reservoir pressure. During this time, downhole gauges record the transient pressure signal. This transient pressure data is analyzed after the well test in order to determine key reservoir parameters of importance such as permeability and skin damage. Also during the course of the well test, downhole fluid samples are often captured and brought to surface after the test is completed. These samples are usually analyzed in a laboratory to determine various fluid properties which are then used to assist with the interpretation of the aforementioned pressure data, establish flow assurance during commercial production phases, and determine refining process requirements among other things.

[0004] It is often important that these fluid samples be maintained near or above the downhole pressure that existed at the time they were captured. Otherwise, as the sample is brought to surface, its pressure would naturally decrease in proportion to the natural hydrostatic gradient of the well. During this reduction in pressure, entrained gas may be released from solution, or irreversible changes such as the precipitation of asphaltenes may occur which will render the captured sample non-representative of downhole conditions. For this reason, downhole samplers often have a means to hold the captured fluid sample at an elevated pressure as it is brought to surface.

[0005] One such means of holding captured fluid samples at an elevated pressure as they are brought to the surface is described in U.S. Patent Application Pub. No. 2008/0148838. Such a tool uses a common pressure source to maintain each sample chamber at a constant pressure preventing phase change degradation of the fluid samples even though it does not maintain the downhole temperature of the samples.

[0006] These sampler assemblies used during well tests are typically deployed in multiple numbers together in a carrier which can position up to 8 or 9 sampler assemblies around the flow path at the same vertical position as described in U.S. patent 6,439,306. The carrier is commonly known as a SCAR (Sampler carrier) assembly and serves as a differential pressure housing. The SCAR assembly typically includes a top sub, a bottom sub, and a housing which couples the top and bottom subs together. The sampler assemblies, including their trigger mechanisms, may be attached to the top sub and enclosed within the SCAR assembly. If it is desired to capture more than one sample at the same time, the SCAR assembly design exposes each sampler to identical surrounding fluid conditions at the time of triggering. Otherwise, if the different samplers were to be distributed a vertical distance along the wellbore, then there can be no assurance that differences in pressure or temperature at the different vertical locations in the wellbore will not affect the well fluid differently causing differences in the captured fluid samples.

[0007] Sampler assemblies of this type have traditionally been triggered using either timer mechanisms programmed at surface before the test or by rupture disks which are burst to capture a sample by the application of annulus pressure from a pressure source at the surface. An example of one timer system can be seen in U.S. Patent 5,103,906, which also employs a rupture disk. An example of the rupture disk design can be found in U.S. Patents 6,439,306, 6,450,263, and 7,562,713. The rupture disks when burst, may allow annulus fluid to enter a chamber which contains a piston. The opposing side of the piston is traditionally exposed to an atmospheric chamber. The pressure differential between annulus pressure and the atmospheric chamber generates a force on the piston which is attached to a pull rod which then moves with the piston to open a regulating valve which begins the fluid sampling process as described in U.S. 6,439,306.

[0008] When the samplers are triggered using rupture disks and a pressure source from the surface in this fashion and it is desired to take samples at different times, many different trigger mechanisms with multiple rupture disks having different burst pressures are needed. Because each disk has an accuracy range associated with it, and it is further desirable to have an unused safety range of pressure between each disk to avoid inadvertently bursting the wrong disk, and because other tools in the test string also rely on this same method for actuation, it is often the case that the maximum allowable casing pressure limits the number of disks that can be deployed in the test string. To overcome this limitation, samplers have traditionally been triggered all at once or in a limited number of combined groups. This restriction limits the flexibility of being able to take many samples at different times during a well test.

[0009] Wireless modems for downhole use exist. Exemplary wireless modems use various communication mediums such as acoustic waves, electromagnetic waves or pressure pulse. Acoustic modems suitable for downhole use are provided with an acoustic transceiver for wireless communication while the acoustic modem is downhole,

[0010] Such a wireless modem can be used to form a wireless triggering system for a downhole fluid sampler. The wireless trigger can be fitted to multiple samplers permitting complete flexibility in choosing when, and in what combination, to fire the downhole samplers, and thus removing the aforementioned casing pressure limitations associated with conventional rupture disk-fired samplers.

[0011] Preparing individual sampler assemblies can require substantial time. Each individual sampler assembly having an acoustic modem and associated trigger must be programmed and the sampler tested for leaks. The sampler assemblies must also be sealed within the SCAR assembly prior to downhole deployment. Once the samplers have been assembled in the SCAR assembly, there is no longer physical access to the individual samplers. Therefore, further testing and reconfiguration of the sampling assembly is limited because a sampling assembly must be uninstalled in order to be tested or reconfigured. It would be advantageous to be able to communicate with the individual samplers having acoustic modems and associated triggers while the assembled SCAR assembly is at the surface without disassembling it.

[0012] An acoustic modem forming part of a sampler trigger will typically have a port for forming a wired communication link with a computer while the acoustic modem is at the surface. The wired communication link is used for testing and configuring the acoustic modem before the acoustic modem is installed within a housing which may form a section of tubing, such as a mandrel. Once the acoustic modem is installed within the housing, the port is enclosed and unavailable unless the acoustic modem is removed from the housing.

[0013] It would therefore be useful to have a method and device to communicate with a wireless modem configured for use in a wellbore after the wireless modem has been mounted within a housing but prior to deployment in the wellbore so that the programming of the wireless modem and/or a downhole tool connected thereto could be modified without disassembly.

BRIEF DISCLOSURE OF THE INVENTION

[0014] In a first aspect, an apparatus is disclosed. The apparatus is made of a surface communication system for communicating wirelessly with a first wireless modem mounted within a section of tubing, and configured to communicate wirelessly with a second wireless modem through a tubing including the section of tubing and within a well at a distance in excess of 500 feet , comprising: a transceiver assembly adapted to be positioned on the section of tubing and in close proximity with the first wireless modem; transmitter electronics configured to provide low power signals to the transceiver assembly to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and receiver electronics configured to receive and interpret high power signals from the transceiver assembly.

[0015] In a second aspect, a method is disclosed. The method comprises the steps of: programming a surface communication system with at least one instruction to be transmitted to a first wireless modem, the first wireless modem configured to communicate wirelessly with a second wireless modem within a well at a distance in excess of 500 feet; placing a transceiver assembly of the surface communication system in close proximity to the first wireless modem prior to deployment of the first wireless modem in the well; and transmitting a low power wireless signal from the transceiver assembly to the first wireless modem including the at least one instruction.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Certain embodiments of the present invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:

[0017] Figure 1 shows a schematic view of an acoustic telemetry system according to an embodiment of the present invention;

[0018] Figure 2 shows a schematic of an acoustic modem as used in accordance with the present disclosure;

[0019] Figure 3 is a longitudinal sectional view of a sampling apparatus in accordance with an embodiment described herein;

[0020] Figure 4A is a cross-sectional view of the sampling apparatus taken along the lines 4A-4A depicted in Figure 3;

[0021] Figure 4B is a cross-sectional view of the sampling apparatus taken along the lines 4B-4B depicted in Figure 3;

[0022] Figure 5 is a diagrammatic view of a wireless communication system according to an embodiment of the present disclosure;

[0023] Figure 6 is a block diagram of a wireless transceiver of the wireless communication system depicted in Figure 5; and

[0024] Figure 7 is a diagrammatic view of another version of a wireless communication system described within the present disclosure.

DETAILED DESCRIPTION

[0025] A surface communication system described herein with reference to Figures 5, 6 and 7 is configured to wirelessly communicate with a wireless modem prior to deployment of the modem within a wellbore. This is particularly applicable to downhole tools and communication systems which are used in testing installations such as are used in oil and gas wells or the like.

[0026] Figure 1 shows a schematic view of a testing installation. In particular, once a well 10 has been drilled through a formation, the drill string can be used to perform tests, and determine various properties of the formation through which the well 10 has been drilled. In the example of Figures 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 preferable to place a sampling apparatus 13 in the well close to 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, drill string, production tubing, or the like (collectively, tubing 14) which extends from well-head equipment 16 at the surface.(or sea bed in subsea environments) down inside the well 10 to a zone of interest. The well-head equipment 16 can include blow-out preventers and connections for fluid, power and data communication.

[0027] A packer 18 is positioned on the tubing 14 and can be actuated to seal the borehole around the tubing 14 at the region of interest. Various pieces of downhole equipment 20 are connected to the tubing 14 above or below the packer 18. The downhole equipment 20 may also be referred to herein as a "downhole tool". In any event, the downhole equipment 20 may include, but is not limited to: additional packers; tester valves; circulation valves; downhole chokes; firing heads; TCP (tubing conveyed perforator) gun drop subs; samplers; pressure gauges; downhole flow meters; downhole fluid analyzers; and the like.

[0028] The surface communication system will be discussed in detail below by way of example with the sampling apparatus 13 being a particular type of downhole equipment 20.

[0029] In the embodiment of Figure 1, a tester valve 24 is located above the packer 18, and the sampling apparatus 13 is located below the packer 18, although the sampling apparatus 13 could also be placed above the packer 18 if desired. The tester valve 24 is connected to a wireless modem 25Mi+1. A gauge carrier 28a may also be placed adjacent to tester valve 24, with each pressure gauge also being associated with an acoustic modem. As will be discussed in more detail below with reference to Figures 2 and 3, the sampling apparatus 13 includes a plurality of the wireless modems 25Mi+(2-9). The wireless modems 25Mi+(1-9), operate to allow electrical signals from the tester valve 24, the gauge carrier 28a, and the sampling apparatus 13 to be converted into acoustic signals for transmission to the surface via the tubing 14, and to convert acoustic tool control signals from the surface into electrical signals for operating the tester valve 24 and the sampling apparatus 13. The term "data," as used herein, is meant to encompass control signals, tool status, and any variation thereof whether transmitted via digital or analog.

[0030] Figure 2 shows a schematic of the wireless modem 25Mi+2 in more detail. The modem 25Mi+2 comprises a housing 30 supporting a transceiver assembly 32 which can be a piezo electric actuator or stack, and/or a magnetorestrictive element which can be driven to create an acoustic signal in the tubing 14. The modem 25Mi+2 can also include an accelerometer 34 and/or monitoring piezo sensor 35 for receiving acoustic signals. Where the modem 25Mi+2 is only required to receive acoustic messages, the transceiver assembly 32 may be omitted. The wireless modem 25Mi+2 also includes transmitter electronics 36 and receiver electronics 38 located in the housing 30 and power is provided by a power source 40, such as one or more lithium batteries. Other types of power supply may also be used. For configuration and testing at the surface, the wireless modem 25Mi+2 includes a port 41 connected to the transmitter electronics 36 and the receiver electronics 38 for forming a wired communication link with a. computer (not shown).

[0031] The transmitter electronics 36 are arranged to initially receive an electrical output signal from a sensor 42, for example from the downhole equipment 20 provided from an electrical or electro/mechanical interface. The sensor 42 can be a pressure sensor to monitor a nitrogen charge as discussed below, or a position sensor to track a displacement of a piston which controls a sample fluid displacement in a sampler assembly discussed below. The sensor 42 may not be located in the housing 30 as indicated in Fig 2. For example, the sensor 42 can be located in the sampler assembly. For example, the sensor may connect to the sampler trigger PCB which would in turn connect to the modem as discussed below. Such signals are typically digital signals which can be provided to a micro-controller 43 which modulates the signal in any number of known ways such as PSK, QPSK, QAM, and the like. The micro-controller 43 can be implemented as a single micro-controller or two or more micro-controllers working together. In any event, the resulting modulated signal is amplified by either a linear or non-linear amplifier 44 and transmitted to the transceiver assembly 32 so as to generate an acoustic signal (which is also referred to herein as an acoustic message) in the material of the tubing 14.

[0032] The acoustic signal passes along the tubing 14 as a longitudinal and/or flexural wave and comprises a carrier signal with an applied modulation of the data received from the sensors 42. The acoustic signal typically has, but is not limited to, a frequency in the range 1-10 kHz, preferably in the range 1-5 kHz, and is configured to pass data at a rate of, but is not limited to, about 1 bps to about 200 bps, preferably from about 5 to about 100 bps, and more preferably about 50 bps. The data rate is dependent upon conditions such as the noise level, carrier frequency, and the distance between the repeaters. A preferred embodiment of the present disclosure is directed to a combination of a short hop wireless modems 25Mi-l, 25M and 25Mi+1 for transmitting data between the surface and the downhole equipment 20, which may be located above and/or below the packer 18. The wireless modems 25Mi-1 and 25M can be configured as repeaters of the acoustic signals. Other advantages of the present system exist.

[0033] The receiver electronics 38 of the wireless modem 25Mi+1 are arranged to receive the acoustic signal passing along the tubing 14 produced by the transmitter electronics 36 of the wireless modem 25M. The receiver electronics 38 are capable of converting the acoustic signal into an electric signal. In a preferred embodiment, the acoustic signal passing along the tubing 14 excites the transceiver assembly 32 so as to generate an electric output signal (voltage); however, it is contemplated that the acoustic signal may excite the accelerometer 34 or the additional transceiver assembly 32 so as to generate an electric output signal (voltage). This signal is essentially an analog signal carrying digital information. The analog signal is applied to a signal conditioner 48, which operates to filter/condition the analog signal to be digitalized by an A/D (analog-to-digital) converter 50. The A/D converter 50 provides a digitalized signal which can be applied to a microcontroller 52. The microcontroller 52 is preferably adapted to demodulate the digital signal in order to recover the data provided by the sensor 42, or provided by the surface. The type of signal processing depends on the applied modulation (i.e. PSK, QPSK, QAM, ant the like).

[0034] The modem 25Mi+2 can therefore operate to transmit acoustic data signals from sensors 42 in the downhole equipment 20 along the tubing 14. In this case, the electrical signals from the downhole equipment 20 are applied to the transmitter electronics 36 (described above) which operate to generate the acoustic signal. The modem 25Mi+2 can also operate to receive acoustic control signals to be applied to the sampling apparatus 13. In this case, the acoustic signals are demodulated by the receiver electronics 38 (described above), which operate to generate the electric control signal that can be applied to the sampling apparatus 13.

[0035] Returning to Fig. 1, in order to support acoustic signal transmission along the tubing 14 between the downhole location and the surface, a series of the wireless modems 25Mi-I and 25M, etc. may be positioned along the tubing 14. The wireless modem 25M, for example, operates to receive an acoustic signal generated in the tubing 14 by the modem 25Mi-1 and to amplify and retransmit the signal for further propagation along the tubing 14. The number and spacing of the wireless modems 25Mi-1 and 25M will depend on the particular installation selected, for example on the distance that the signal must travel. A typical spacing between the wireless modems 25Mi-1, 25M, and 25Mi+1 is around 1,000 ft, but may be much more or much less 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 52 of the transmitter electronics 36 and used to drive the transceiver assembly 32 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.

[0036] 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 present invention.

[0037] The wireless modems 25M, 25Mi-1, and 25Mi+1 will either listen continuously for any incoming signal or may listen from time to time.

[0038] The acoustic wireless signals, conveying commands or messages, propagate in the transmission medium (the tubing 14) in an omni-directional fashion, that is to say up and down. It is not necessary for the modem 25Mi+1 to know whether the acoustic signal is coming from the wireless modem 25M above or one of the wireless modems 25Mi+(2-9) below. The destination of the acoustic message is preferably embedded in the acoustic message itself. Each acoustic message contains several network addresses: the address of the wireless modem 25Mi-1, 25M, 25Mi+1, or 25Mi+(2-9) originating the acoustic message and the address of the wireless modem 25Mi-1, 25M or 25Mi+1 that is the destination. Based on the addresses embedded in the acoustic messages, the wireless modem 25Mi-1, 25M, or 25Mi+1 functioning as a repeater will interpret the acoustic message and construct a new message with updated information regarding the wireless modem 25Mi-1, 25M, 25Mi+1, or 25Mi+(2-9) that originated the acoustic message and the destination addresses. Acoustic messages will be transmitted from the wireless modems 25Mi-1, 25M, and 25Mi+1 and slightly modified to include new network addresses.

[0039] Referring again to Figure 1, a surface wireless modem 28d is provided at the head equipment 16 which provides a connection between the tubing 14 and a data cable or wireless connection 54 to a control system 56 that can receive data from the downhole equipment 20 and provide control signals for its operation.

[0040] In the embodiment of Figure 1, the acoustic telemetry system is used to provide communication between the surface and the downhole location.

Sampling Apparatus 13

[0041] Referring to Figures 3, 4A and 4B, the sampling apparatus 13 is preferably mounted as part of the tubing 14, and includes a carrier 60 having a first sub 62, a second sub 64, and a housing section 66 coupled between the first sub 62 and the second sub 64. An inner bore 70 is defined through the carrier 60 and includes an inner passageway 72 of the first sub 62, and an inner passageway 74 of the second sub 64. According to one embodiment, the housing section 66 defines the inner bore 70 inside the sampling apparatus 13 in which one or more sampler assemblies 80 may be positioned. In the illustrated embodiment, eight sampler assemblies 80a-h (See Figure 4) are positioned in the inner bore 70 although more or less of the sampler assemblies 80 can be provided. As will be discussed in more detail below, each of the sampler assemblies 80 has a first end 82, as depicted in Figure 3 by 82c and 82g, which is connected to the first sub 62, and a second end 84 which is connected to a centralizer assembly 85 which is positioned just above the second sub 64.

[0042] It should be noted that each of the sampler assemblies 80a-h is substantially similar in construction and function and so only one of the sampler assemblies 80c will be described in detail hereinafter. In general, the sampler assembly 80c is provided with the wireless modem 25Mi+2, the power source 40c, an actuator 92c, a sampler device 94c, a swivel assembly 96c, a first connector 98c, and a second connector 100c, all of which are rigidly connected together to form an integral assembly. The second connector 100c is connected to the centralizer assembly 85. The centralizer assembly 85 is positioned within the housing section 66 to allow the sampler assembly 80c to expand and contract with changes in temperature.

[0043] Each of the sampler devices 94 preferably forms an independent self-contained system including a nitrogen charge 102. The prior art uses a single nitrogen reservoir to supply all samplers. Hence a failure of their nitrogen storage system would result in a much larger release of energy (i.e., explosion) than the nitrogen charge 102 for each of the sampler devices 94.

[0044] The sampling apparatus 13 is preferably a modular tool made up of the carrier 60 and a plurality of the sampler assemblies 80a-h which can be independently controlled by the surface using the wireless modems 25Mi+(2-9). The wireless modem 25Mi+2, for example, communicates with the actuator 92 for supplying control signals to the actuator 92 and for returning a signal to the surface confirming a sampling operation. Incorporating the wireless modem 25Mi+(2-9) within the sampler assemblies 80a-h, for example, permits independent actuation of individually addressed sampler devices 94, via surface activation while also configured to provide receipt of actuation and other diagnostic information. The diagnostic information can include, for example, status of the transmitter electronics 36, status of the receiver electronics 38, status of telemetry link, battery voltage, or an angular position of motor shaft as described hereinafter. In the embodiment shown in Figure 3, the actuator 92 is integrated both electrically and mechanically with the wireless modem 25Mi+2. Each sampler assembly 80a-h is preferably fully independent providing full individual redundancy. In other words, because each sampler assembly 80a-h has its own wireless modem 25Mi+(2-9), power source 40, actuator 92, and sampler device 94, full redundancy is achieved. For example, if for any reason one of the sampler assemblies 80a-h were to fail, the remaining sampler assemblies 80a-h can be fired fully independently.

[0045] With respect to the sampler assembly 80c, the first connector 98c is positioned at the first end 82c and preferably serves to solidly connect the wireless modem 25Mi+2 to the first sub 62 to provide a suitable acoustic coupling into the tubing 14. The first connector 98c can be implemented in a variety of manners, but for simplicity and reliability the first connector 98c is preferably implemented as a threaded post which can engage with a threaded hole within the first sub 62. The second connector 100c is positioned at the second end 84c and preferably serves to connect the sampler device 94c to the centralizer assembly 85 which serves to maintain the second end 84c of the sampler device 94c out against the housing section 66. The second connector 100c is preferably non-rotatably connected to the centralizer assembly 85, and for this reason the sampler assembly 80c is provided with the swivel assembly 96c to permit installation of the sampler assembly 80c into the first sub 62.

[0046] More particularly, to install the sampler assembly 80c within the carrier 60, the second connector 100c is first attached to the centralizer assembly 85, and then the first connector 98c is positioned within the threaded hole within the first sub 62. The swivel assembly 96c permits the wireless modem 25Mi+2, power source 40c, actuator 92c and sampler device 94c to be rotated to thread the first connector 98c into the threaded hole of the first sub 62 or the second sub 64 while the second connector 100 remains fixed to the centralizer. The swivel assembly 96c can be located in various positions within the sampler assembly 80c.

[0047] The power source 40c preferably includes one or more batteries, such as Lithium-thionyl chloride batteries with suitable circuitry for supplying power to the wireless modem 25Mi+2, as well as the actuator 92c. The power source 40c may also be provided with circuitry for de-passivating the battery before the actuator 92c is enabled to cause the sampler device 94c to collect a sample. Circuitry for de-passivating a battery is known in the art and will not be described in detail herein.

[0048] The power source 40c can be shared between the wireless modem 25Mi+2 and the actuator 92c which provides for a shorter and less expensive power source 40c. That is, assuming that the wireless modem 25Mi+2 and the actuator 92c use a voltage level greater than ∼ 5 volts to operate and that a single battery cell using technology suitable for downhole applications typically produces a voltage level ∼ 3 volts then at least 2 battery cells are required in series to produce a voltage greater than ∼ 5-6 volts. If the wireless modem 25Mi+2 and the actuator 92c retain its own battery system then each would require at least 2 cells in series to provide an adequate voltage level, which would increase the length of the power source 40c.

[0049] The mechanical module 106c is connected to the sampler device 94c for actuating the sampler device 94c to collect a sample. The electronics module 108c functions to interpret the control signals received from the wireless modem 25Mi+2, and to provide one or more signals to cause the mechanical module 106c to actuate the sampler device 94c. In a preferred embodiment, the electronics module 108c can be provided with one or more microcontrollers, and other circuitry for controlling the mechanical module 106c. Methods of making and using the mechanical module 106c and the electronics module 108c are known in the art and so a detailed explanation of same is not necessary to teach one skilled in the art how to make and use the sampler assembly 80c.

Surface Communication System

[0050] Shown in Figures 3 and 5 are exemplary embodiments of a surface communication system 120 constructed in accordance with the present disclosure. In general, the surface communication system 120 is provided with a transceiver assembly 122, an electronics package 124 and a communication link 126 connecting the transceiver assembly 122 to the electronics package 124. The transceiver assembly 122 can be a pressure actuator for pulse telemetry, an antenna for electromagnetic telemetry, or a piezo electric actuator or stack, and/or a magnetorestrictive element which can be driven to provide an acoustic signal. The transceiver assembly 122 will be described herein as providing acoustic signals which form stress waves within a carrier, such as the tubing 14. The tubing 14 may be constructed of steel in a manner known in the art.

[0051] The wireless modems 25Mi+(2-9) are mounted within a section of the tubing 14 formed by the housing section 66, the first sub 62, and the second sub 64. The wireless modems 25Mi+(2-9) are configured to communicate wirelessly with another (or second) wireless modem through the tubing 14 including the section of tubing 14 and within the well 10 at a distance in excess of 500 feet. In general, the electronics package 124 and the transceiver assembly 122 are adapted to wirelessly communicate with one or more of the wireless modems 25Mi+(2-9) while the wireless modems 25Mi+(2-9) are at the surface and prior to being deployed within the well 10.

[0052] More particularly, the transceiver assembly 122 is positioned in close proximity, e.g., within 20 feet, to one or more of the wireless modems 25Mi+(2-9). For example, as depicted in Figure 3 the transceiver assembly 122 is positioned on the housing section 66 generally adjacent to the wireless modems 25Mi+(2-9) such that stress waves generated by the transceiver assembly 122 are introduced into the housing section 66. The stress waves travel to the wireless modems 25Mi+(2-9) via the housing section 66, and the first sub 62. Likewise, stress waves introduced by the wireless modems 25Mi+(2-9) travel to the transceiver assembly 122 via the first sub 62 and the housing section 66. The stress waves generated by the transceiver assembly 122 and introduced by the wireless modems 25Mi+(2-9) can be indicative of data, addresses, instructions, and/or the like such that bidirectional communication is provided between the transceiver assembly 122 and the wireless modems 25Mi+(2-9).

[0053] The transceiver assembly 122 converts the stress waves provided by the wireless modems 25Mi+(2-9) into electrical signals and transmits the electrical signals to the electronics package 124 for interpretation. Likewise, the transceiver assembly 122 receives electrical signals from the electronics package 124 and convert such electrical signals into stress waves to be communicated to the wireless modems 25Mi+(2-9). Thus, it can be seen that the surface communication system 120 permits the operator to communicate with one or more of the wireless modems 25Mi+(2-9) wirelessly and after the sampling apparatus 13 has been fully assembled. In particular, once the sampling apparatus 13 has been fully assembled, the housing section 66 covers and seals the ports 41 of the wireless modems 25Mi+(2-9).

[0054] As discussed above, the wireless modems 25Mi+(2-9) can be configured to communicate through the tubing 14 at distances in excess of 500 feet. In order to communicate with the wireless modems 25Mi+(2-9) at much closer distances and without requiring reconfiguration of the wireless modems 25Mi+(2-9), the transmitter electronics 130 (Figure 5) is configured to provide low power signals to the transceiver assembly 122 to cause the transceiver assembly 122 to generate low power wireless signals into the section of tubing 14 to be received and interpreted by the one or more of the wireless modem 25Mi+(2-9). The receiver electronics 132 (Figure 6) is configured to receive and interpret high power signals from the transceiver assembly 122. The high power signals are generated by one or more of the wireless modems 25Mi+(2-9) to propagate in excess of 500 feet within the tubing 14. Signal power diminishes as length from the wireless modems 25Mi+(2-9) increase. Thus, the high power signals received by the transceiver assembly 122 (that is in close proximity to the wireless modems 25Mi+(2-9) at the surface) are much stronger than the same signals received by another wireless modem when the sampling apparatus 13 is deployed in the well 10. As will be explained in more detail below, the reception and interpretation of the high power signals can be implemented by the receiver electronics 132 by using a first amplifier 136 having a low gain or even negative gain to provide electrical signals from the transceiver assembly 122 to a first processing device 138.

[0055] Because the time required to prepare the individual sampler assemblies 80, charge the sampler assemblies 80 with nitrogen, and test for leaks around the housing section 66 can be quite long, it is undesirable to disassemble the sampling apparatus 13 to provide access to the hardwired ports 41 of the wireless modems 25Mi+(2-9). Therefore, it is advantageous to be able to communicate with the individual sampler assemblies 80 while the assembled sampling apparatus 13 is at the surface without disassembling anything. For example, if there is an unforeseen delay in rig operations, it may be necessary to put the electronic systems into deep sleep mode in order to preserve battery power so as not to reduce the time that the sampling apparatus 13 can operate downhole. The surface communication system 120 preferably allows communication with the electronics module 108 by placing the transceiver assembly 122 against the housing section 66 and/or the first sub 62 or the second sub 64 and more generally allows communication with any wireless-enabled tool when the wireless-enabled tool is at the surface, even after the wireless-enabled tool has been assembled or otherwise deeply embedded within another tool.

[0056] Each wireless-enabled tool, such as the sampling apparatus 13, will require some degree of configuration before being run downhole. For example, the wireless modems 25Mi+(2-9) can be configured so that the wireless modems 25Mi+(2-9) understand the intended function of the testing application and instructions regarding the particular sampler device 94 that the particular wireless modems 25Mi+(2-9) are connected to. The wireless modems 25Mi+(2-9) can be configured at the surface for this functionality. In particular, memory logs of the wireless modems 25Mi+(2-9) can be initialized, and any desired time delay before the sampler device 94 becomes functional can be programmed. Finally, time clocks of the wireless modems 25Mi+(2-9) and the electronics module 108 can be synchronized with a surface data acquisition/control computer. This initial configuration can be performed on the wireless modems 25Mi+(2-9) from inside a lab cabin by physically connecting the wireless modems 25Mi+(2-9) to a surface control computer with a cable. Once configured, the wireless modems 25Mi+(2-9) can then be moved outside for assembly with the sampler devices 94. The sampler devices 94 can then be,charged with nitrogen, for example, and then connected to the first sub 62, second sub 64, and the housing section 66. Finally, final pressure checks will be usually made - all of which represent a significant amount of preparation effort and time.

[0057] Should any unforeseen change in rig schedule occur, the surface communication system 120 can be utilized to reprogram a time delay for the wireless modems 25Mi+(2-9) and/or the electronics module 108 or temporarily switch them off. Hence, the surface communication system 120 is advantageous since the transceiver assembly 122 can be placed onto the outside surface of the assembled sampling apparatus 13 and acoustically transmit parameter changes and to check that the sampling apparatus 13 is functioning properly.

[0058] One particularly desirable application for the surface communication system 120 is to manage deep-sleep modes before running tools in the well 10 in order to preserve battery autonomy. For example, the sampling apparatus 13 could be put into a deep sleep state for a predetermined period of time, during which all acoustic processing is stopped and only a low power clock function is kept running, thereby reducing battery consumption to an absolute minimum. After the designated time delay, the sampling apparatus 13 would awaken and resume acoustic processing, allowing communication via the surface communication system 120. To provide greater flexibility in managing rig delays, the sampling apparatus 13 could "wake-up" every 15 minutes or so to an idle state at pre-programmed times to check for a communication signal from the surface communication system 120. If no signal is present, the sampling apparatus 13 would then revert to sleep mode. The surface communication system 120 may also be used on a rig floor to make a final check of all wireless enabled tools before they are lowered through the rotary table.

[0059] Exemplary states of the wireless modems 25Mi+(2-9) include the sleep state and the idle state discussed above. In the sleep state, one or more electronic components or functionalities are powered off while certain electronic components or functionalities are powered on. Depending on the microcontroller and programmed logic, examples of the portion of the wireless modems 25Mi+(2-9) (i.e., electronic components and/or functionalities) that may be powered off or on may include, certain peripheral components, the RAM, and possibly the MCU clock. In the idle state, the wireless modems 25Mi+(2-9) are powered on and waited for a command.

[0060] The surface communication system 120 is preferably portable and suitable for Zone 0 operation. It could either be powered by battery or via a power cable. A hand-carryable enclosure, containing one or more batteries, the transceiver assembly 122, and/or the electronics package 124 can be used. The electronics package 124 can be connected via a short cable (communication link 126) to the transceiver assembly 122, which may have a magnetic base for maintaining the transceiver assembly 122 securely attached to the housing section 66, for example. The electronics package 124 may provide simple built-in tool-check commands, or the electronics package 124 may have the ability to support more complex programming/configuration of any acoustic-enabled downhole tools, such as the sampling apparatus 13. The electronics package 124 can operate autonomously or the electronics package 124 could be connected to a user interface device 140, such as a portable computer, as shown in Figure 5 to provide an additional communication interface and display or processing capabilities.

[0061] Shown in Figure 6 is a block diagram of the surface communication system 120. The electronics package 124 of the surface communication device 120 includes transmitter electronics 130 and receiver electronics 132. Power for the transmitter electronics 130 and the receiver electronics 132 can be provided by means of one or more battery, such as a lithium battery 134. Other types of power supply may also be used.

[0062] The transmitter electronics 130 are arranged to initially receive an electrical output signal from the user interface device 140 indicative of a predetermined command or instruction to be provided to one or more of the wireless modems 25Mi+(2-9). For example, the command can identify one or more of the wireless modems 25Mi+(2-9), as well as include instructions to place one or more of the wireless modems 25Mi+(2-9) into a deep sleep mode for a predetermined period of time, during which all acoustic processing is stopped and only a low power clock function is kept running to reduce battery consumption as discussed above.

[0063] Such signals are typically digital signals which can be provided to a processing device 142, such as a logic device or a microprocessor. The logic device may not operate on a set of instructions stored on a non-transitory computer readable medium. Exemplary logic devices include a field programmable gate array or an application specific integrated circuit. The microprocessor operates on a set of instructions stored on a non-transitory computer readable medium. The microprocessor can be implemented in various forms, such as one or more microprocessor, micro-controller or the like. In either case, the processing device 142 modulates the signal in any number of known ways such as PSK, QPSK, QAM, and the like. The processing device 142 can be implemented as a single device, or two or more devices working together. The transmitter electronics 130 and the receiver electronics 132 are configured to use the same data rate, and encoding scheme(s) as the wireless modems 25Mi+(2-9) to permit communication therebetween.

[0064] The resulting modulated signal is amplified by either a linear or non-linear amplifier 144 and transmitted to the transceiver assembly 122 so as to generate an acoustic signal (which is also referred to herein as an acoustic message) in the material of the sampling apparatus 13. The amplifier 144 is adapted to produce electrical signals to cause the transceiver assembly 122 to generate low power signals for reception by the wireless modems 25Mi+(2-9). The primary reason for transmitting at low or reduced power by the surface communication system 120 with the wireless modems 25Mi+(2-9) is to avoid saturating the transceiver assembly 32 when the surface communication system 120 is placed very near the downhole tool. Low power signals, as used herein, refers to signals having a power in a range between .1 to 3 watts, and preferably from .1 to 1.5 watts.

[0065] The user interface device 140 can be one or more devices capable of receiving operator input and then providing signals to the processing device 142. For example, the user interface device 140 can be a keyboard, keypad, microphone, tablet and/or the like. Alternatively, the user interface device 140 can be a separate portable computer as set forth in Figure 5.

[0066] The surface communication system 120 can therefore operate to transmit acoustic data signals from a user, either preprogrammed or from a user input device, such as a portable computer, to the wireless modems 25Mi+(2-9) prior to deployment. In this case, electrical signals from the user are applied to the transmitter electronics 130 (described above) which operate to generate the acoustic signal. The surface communication system 120 can also operate to receive acoustic response signals from the wireless modems 25Mi+(2-9). In this case, the acoustic signals are demodulated by the receiver electronics 132 (described above), which operate to generate the electrical response signal giving information about the state of particular ones of the wireless modems 25Mi+(2-9).

[0067] Further, it should be understood that the modems and the transceiver assembly have been described herein by way of example as acoustic modems using stress waves as a communication medium. It should be understood that the modems and the transceiver assembly 122 can use other types of wireless mediums, such as pressure pulse signals, electromagnetic signals, mechanical signals and the like. As such, any type of telemetry may be used to pass signals between the transceiver assembly and the modems.

[0068] Shown in Figure 7 is another example of a surface communication system 120a constructed in accordance with the present disclosure. The surface communication system 120a operates in a similar manner as the surface communication system 120 discussed above, but is implemented utilizing a commercially available portable device, such as a cellular telephone sold under the trademark IPHONE version 4 and produced by the Apple Corporation. The wireless communication system 120a can be provided with a speaker 150, a microphone 152, a display 154, one or more communication devices 156, and input unit 158, a non-transitory computer readable medium such as a memory 159 and a processor 160. The speaker 150, the microphone 152, the display 154, the one or more communication devices 156, the input unit 158 and the memory 159 (collectively devices) are adapted to communicate either directly or indirectly with the processor 160 such that the processor 160 can either provide data and/or read data read data from such devices. The surface communication system 120a may also be provided with a volume control 162 for a purpose to be described hereinafter. The volume control 162 can either be a physical switch, or such functionality can be programmed into or provided by the processor 160.

[0069] The speaker 150 and a microphone 152 form parts of a transceiver assembly 164 for communicating with the wireless modems 25Mi+(2-9) by the housing section 66, first sub 62 and second sub 64. In particular, the microphone 152 can be used to receive and forward acoustic signals to the processor 160, and the speaker 150 can be driven by the processor 160 to produce acoustic signals. The volume control 162 controls the level of the acoustic signals that are generated by the speaker 150. The processor 160 can be constructed in a similar manner as the processing device 142, discussed above.

[0070] The display 154 can be a liquid crystal display or any other display suitable for use in a portable device. The one or more communication devices 156 can be a cellular telephone, and/or a short range communication system such as that sold under the trademark Bluetooth. Communication devices such as cellular telephones and/or the like are well known to those skilled in the art and so a detailed description of how to make and use same is not deemed necessary herein. The input unit 158 can be a keyboard and/or a touchscreen and serves to provide user input to the processor 160. The memory 159 can be random access memory, flash memory or the like.

[0071] In use, the microphone 152 can be used to record acoustic signals indicative of predetermined instructions and save such acoustic signals in a file on the surface communication system 120a. Once the acoustic signals have been recorded and saved, files can be selected utilizing the input unit 158 and played by the speaker 150 to communicate such acoustic signals to the wireless modems 25Mi+(2-9). For example, one of the files can be selected and then actuated for playing by the speaker 150. The surface communication system 120a can then be placed on to the housing section 66 of the sampling apparatus 13 such that the housing section 66 receives the acoustic signals generated by the speaker 150 and conveys such acoustic signals via stress waves to the wireless modems 25Mi+(2-9).

[0072] Although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of the present invention. Accordingly, such modifications are intended to be included within the scope of the present invention as defined in the claims.

Claims

1. A surface communication system for communicating wirelessly with a first wireless modem mounted within a section of tubing, and configured to communicate wirelessly with a second wireless modem through a tubing including the section of tubing and within a well at a distance in excess of 500 feet, comprising:

a transceiver assembly adapted to be positioned on the section of tubing and in close
proximity with the first wireless modem;

transmitter electronics configured to provide low power signals to the transceiver assembly
to cause the transceiver assembly to generate low power wireless signals into the section of tubing to be received and interpreted by the first wireless modem; and receiver electronics configured to receive and interpret high power signals from the
transceiver assembly.

2. The surface communication system of claim 1, wherein the transceiver assembly includes at least one of a piezoelectric element and a magnetorestrictive element.

3. The surface communication system of claim 1, wherein the low power wireless signals are acoustic signals.

4. The surface communication system of claim 1, wherein the transmitter electronics stores at least one acoustic file indicative of a predetermined command.

5. The surface communication system of claim 1, wherein the surface communication system further comprises a user input device passing commands to the transmitter electronics, and wherein the transmitter electronics provides the low power signals responsive to receiving the commands.

6. The surface communication system of claim 1, wherein power levels of the low power signals and the high power signals are predetermined.

7. The surface communication system of claim 1, wherein the transceiver assembly, the transmitter electronics and the receiver electronics are parts of a cellular telephone.

8. A method comprising the steps of:

programming a surface communication system with at least one instruction to be transmitted
to a first wireless modem, the first wireless modem configured to communicate wirelessly with a second wireless modem within a well at a distance in excess of 500 feet;

placing a transceiver assembly of the surface communication system in close proximity to the
first wireless modem prior to deployment of the first wireless modem in the well; and transmitting a low power wireless signal from the transceiver assembly to the first wireless
modem including the at least one instruction.

9. The method of claim 8, wherein programming the surface communication system is defined further as downloading an instruction set to the surface communication system from an external user input device.

10. The method of claim 8, further comprising the step of installing the first wireless modem within a section of tubing.

11. The method of claim 10, wherein the step of placing the transceiver assembly in close proximity to the first wireless modem is defined further as placing the transceiver assembly on the section of tubing.

12. The method of claim 8, wherein the first wireless modem is rigidly mounted within a housing, and wherein the step of placing the transceiver assembly in close proximity with the first wireless modem includes placing the transceiver assembly in contact with a surface of the housing, the housing forming a communication channel to pass the low power wireless signal to the first wireless modem.

13. The method of claim 8, wherein the low power wireless signal is encoded with an instruction to change a configuration of the first wireless modem from a first state to a second state.

14. The method of claim 8, wherein the first wireless modem is a part of a downhole tool having electronics separate from the first wireless modem and in communication with the first wireless modem, and wherein the low power wireless signal is encoded with an address of the first wireless modem, and an instruction to change a configuration of the electronics of the downhole tool from a third state to a fourth state.

15. The method of claim 8, further comprising the step of receiving a confirmation signal from the first wireless modem through stress waves generated by the first wireless modem transmitting acoustic signals.

Drawing