RELATED APPLICATIONS

[0001 ] This patent application claims the benefit of priority to U.S. Provisional Patent Application No. 61/903,943 to Coste et al., filed November 13, 2013, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] It has been estimated that more than 90 percent of producing oil wells require some form of artificial lift. Electric submersible pumps (ESPs) placed downhole in wells are used worldwide to provide such artificial lift. It is estimated that more than 100,000 wells have been fitted or retrofitted with ESPs. Pump surveillance, which includes monitoring, diagnosis, and control of an ESP, is valuable in maximizing both the run time of the pump and the well performance. For this reason, ESPs are fitted with surveillance hardware, such as downhole sensors, which can enable real time analysis. These sensors commonly provide for continuous sampling of pressures, temperatures, vibration, electrical current draw, voltage levels, and flow data. However, many remote wells are located far from usual communication networks and require a human worker to drive to the wells to collect well data. SUMMARY

[0003] Unmanned aerial vehicles (UAVs) for well monitoring and control are provided. An example method includes generating data associated with a well at a location of the well, deploying an unmanned aerial vehicle (UAV) comprising at least a wireless data receiver and a wireless data transmitter, and transferring the data from the location of the well to a data hub at a second location via the UAV. An airborne controller for surveillance and servicing of the well via the UAV includes a processor, a data storage medium, a wireless transceiver, a connection module for autonomously opening a wireless dialogue between a terrestrial telecommunications network of a well on the route and the UAV, and a data downloader for wirelessly retrieving data associated with the well from the terrestrial telecommunications network of the well to the UAV. An example system includes at least one unmanned aerial vehicle (UAV), a transceiver on the UAV for wirelessly communicating with a wireless network of a well, and a data storage medium on the UAV for storing data associated with the well received from the wireless network of the well.

[0004] This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein.

[0006] Fig. 1 is a diagram of an example well system, including ESP string, outfitted for communication with an unmanned aerial vehicle (UAV), including surveillance, monitoring, controlling, diagnosing, calibrating, updating, checking, and repairing of the ESP string and well via the UAV.

[0007] Fig. 2 is a diagram of example UAVs suitable for wireless communication with a well system.

[0008] Fig. 3 is block diagram of an example airborne controller for well surveillance and servicing via an UAV.

[0009] Fig. 4 is a block diagram of an example surface controller for well surveillance and servicing via an UAV.

[0010] Fig. 5 is a diagram of an example UAV well surveillance system.

[001 1 ] Fig. 6 is a diagram of an example stationary airship form of UAV suitable for wireless communication with a well system.

[0012] Fig. 7 is a diagram of example high-altitude forms of UAV suitable for wireless communication with a well system.

[0013] Fig. 8 is an example method of wireless communication with a well system via one or more UAVs. [0014] Fig. 9 is a flow diagram of an example method of well surveillance and servicing via an UAV.

DETAILED DESCRIPTION

[0015] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

[0016] This disclosure describes unmanned aerial vehicles for well monitoring and control. Depending on proprietorship, for a given company only about five percent of wells with production tools and artificial lift devices, such as electric submersible pumps (ESPs), progressive (or progressing) cavity pumps (PCPs), rod pumps, etc., or monitoring systems (e.g., seismic or microseismic monitoring) are monitored at a distance by a surveillance center. This is because many wells are remotely located, far from readily accessible communication networks.

[0017] In an implementation, an example process includesgenerating data associated with a well at a location of the well, deploying an unmanned aerial vehicle (UAV) that includes at least a wireless data receiver and a wireless data transmitter, and transferring the data from the location of the well to a data hub at a second location, via the UAV. The UAV, which is autonomous in the sense of having no human aboard, may be a drone, a fixed-wing airplane, a model airplane, a helicopter, a multi-rotor copter-drone, a hovercraft, a balloon, a dirigible, a tethered dirigible, a blimp, a zeppelin, or a stationary or mobile airship.

[0018] Fig. 1 shows an example well system 100 outfitted for surveillance by an unmanned aerial vehicle (UAV) 102. A UAV 102 may also be referred to as a flying drone or airborne robot. The example well 100 includes production equipment for artificial lift, represented by an example downhole electric submersible pump (ESP) string 104. The ESP string 104 may include a motor 106 and pump 108 with intervening motor protector 110. Multiple instances of these components may be included in the ESP string 104, in sequence. The ESP string 104 may also include multiple gauges, referred to herein as downhole sensors 112. For example, the gauges may include bottomhole pressure and temperature sensors, discharge pressure gauges, distributed temperature sensors, vibration spectral data sensors, differential pressure sensors, strain sensors, proximity sensors, load cell sensors, dirty filter sensors, bearing wear sensors, positional sensors, rotational speed sensors, torque sensors, electrical leakage detectors, wye-point imbalance sensors, chemical sensors, water cut sensors, and so forth. Surface data may include, among other parameters, flow rate, production volume, oil and gas ratios, water cut, viscosity, density, and so forth. The data values of these various sensors, gauges, and surface parameters are referred to herein as "well data." [0019] A well system having production equipment, such as an ESP, intake and discharge pressure gauges, switchgear and an integrated surface panel for control and monitoring of the ESP and downhole operating parameters via wireline is described in U.S. Patent No. 8,527,219, which is incorporated herein by reference in its entirety. The ESP string 104 may include multisensory gauges available in a package, such as for example, the PHOENIX MULTISENSOR XT150 (Schlumberger Technology Corporation, Houston, TX). Multisensory gauges include sensors for monitoring a combination of downhole parameters, such as temperature, flow and pressure.

[0020] A surface controller 114 (and data acquisition system) of the example well system 100 may include or have access to a wireless transmitter and receiver (transceiver) of a wireless network (e.g., WiFi, WiMAX, or other radio frequency communication scheme) 116. The surface controller 114 can wirelessly transmit well information and receive data over the wireless network 116.

[0021 ] The UAV 102 includes an example airborne controller 118 that includes a transceiver (e.g., WiFi enabled) to communicatively connect with the wireless network 116 of the surface controller 114 associated with the well system 100. The onboard airborne controller 118 of the UAV 102 can connect with other compatible wireless networks, such as the wireless networks of different wells, the wireless network of another UAV, stationary airship, or balloon, or the wireless networks of one or more base stations for the UAV 102.

[0022] When the UAV 102 is airborne and in range of the wireless network 116 of the example well system 100, the airborne controller 118 establishes a two-way communication channel with the surface controller 114, and exchanges data, including retrieving data (stored or real time) from the downhole sensors 112, issuing control commands, installing software updates, performing diagnostic and troubleshooting dialogues, initiating calibration instructions, and so forth.

[0023] Fig. 2 shows example UAVs 102 that can carry and transport the example airborne controller 118 for monitoring and controlling ESPs 104 and wells 100. The UAV 102 may be a small fixed-wing, hovering, or copter-like flying drone, or can be a larger robot plane, model, drone, or balloon. The UAV can also be a mobile or tethered airship or dirigible, with a rigid or inflatable structure. Relatively small UAV's 102 may be used for flying routes that cover limited distance or area, such as the DELTAIR DT-18 drone 202 (Deltair-Tech, Toulouse, France). The DT-18 drone 202 can fly about 100-250 km on a battery charge that provides 2-4 hours of flying time. Larger UAVs may be used to fly for long or indefinite-duration periods of time. The larger UAVs may be powered by any combination of battery, capacitor, photovoltaic, or nuclear reaction power sources.

[0024] An EBEE drone 204 can also be used to fulfill the role of the UAV 102, covering an area, for example, of 12 square km or 4.6 square miles in a single flight, or smaller areas at lower altitude (senseFly Ltd, Cheseaux- Lausanne, Switzerland).

[0025] Another example UAV 102, the microdrones md4-1000 aerial vehicle 206, is a miniaturized VTOL aircraft (Vertical Take Off and Landing). This aerial vehicle 206 can fly autonomously for about 90 minutes using microdrones' GPS Waypoint navigation software (microdrones GmbH, Siegen, Germany).

[0026] Fig. 3 shows the example airborne controller 118 of Figs. 1 -2, in greater detail. The illustrated example airborne controller 118 is just one example, for the sake of description. Other configurations may also be used, with variations in the components. The illustrated components are not required to be in one physical module, but may be distributed according to implementation. For example, a transceiver or WiFi component may exist as a discrete physical package.

[0027] The example airborne controller 118, for transport onboard the UAV 102, may include a processor 300, a memory 302, data storage 304, such as a solid state or flash type drive, and a transceiver 306, such as a transmitter and receiver of a WiFi module 308, including a connection module 310 for autonomously sensing and connecting to local wireless networks.

[0028] A navigation system 312 may include a GPS system 314, and flies the UAV 102 based on a route included in a flight plan 316 uploaded to data storage 304 and memory 302, via the WiFi module 308. The current flight plan 316 that provides the current mission for the UAV 102, may be uploaded from a base station for the UAV 102, or may be uploaded during flight, by a surface station or by another UAV 102 that is also in flight.

[0029] The example airborne controller 118 includes a well surveillance module 318 for a combination of functions that may include monitoring, controlling, diagnosing, calibrating, updating, checking, and repairing of the local production or monitoring equipment, ESP system 104, or corresponding well 100. The well surveillance module 318 may include a well identifier 320 to determine wells designated in a route provided by the flight plan 316. In an implementation, the flight plan 316 designates a route, and the well identifier 320 stores the location of wells 100, production devices, monitoring equipment, and ESP systems 104 on that route. In another implementation, the flight plan 316 includes a flying route for the navigation system 312, and separately provides a list of wells 100 and their location coordinates for the well identifier 320 and for the (WiFi) connection module 310.

[0030] Once communicatively connected to a surface controller 114 of a well 100, during flyover, the well surveillance module 318 includes a polling module 322 to open a dialogue with the local surface controller 114. In an implementation, the polling module 322 signals the local surface controller 114 with an initial query, analogous to "do you have anything to report?" The surface controller 114 may only have routine production and flow history, records, sensor data, and quality control information to upload to the UAV 102. But the surface controller 114 may also have one or more error messages, faults, warnings, or notices to report. [0031 ] In an implementation, the surface controller 114 may maintain persistent or semi-persistent communication links with a terrestrial telecommunications network by using the UAVs 102, either small or large, tethered or free-flying, as one or more repeaters. Multiple UAVs 102 may be linked together through a higher-altitude wireless network to provide extended coverage at greater distances from the terrestrial telecommunication interface point. In such a scenario, the surface controllers 114 may utilize traditional communication protocols with few or no provisions needed to deal with the UAV-facilitated aerial routing and/or repeating of the data.

[0032] For the sensor data, routine history, records, and quality control information, the well surveillance module 318 of the UAV 102 may include a sensor data downloader 324 to retrieve the collected sensor data. The raw sensor data may be stored onboard the UAV 102 in data storage 304 as "well data" 326 (including ESP data, surface data, production tool data, and local monitoring data). The well data 326 is downloaded later at a base station or surveillance center for processing by a computer or human supervisor to discern well production, malfunctions, and desirability of updates for the gauges, ESP string 104, production tools, monitoring equipment, and so forth.

[0033] A diagnostics engine 328 may be included in the well surveillance module 318 to analyze the well data 326 and commence proactive dialogue and intervention during flyby of the UAV 102. The diagnostics engine 328 may signal the navigation system 312 to opt into a holding pattern around the well 100 if the dialogue and interventions are calculated to use more time than allowed by a straight-line flyover. In an implementation, depending on UAV 102, the navigation system 312 can also slow down the airspeed of the UAV 102 to provide more time for dialogue and intervention, or can hover the UAV 102 in a stationary position if the UAV 102 is a copter-type drone.

[0034] A servicing module 330 may be included in the well surveillance module 318 to provide autonomous interventions for the well 100, production tools, monitoring equipment, or ESP string 104. An adjustment module 332 may send commands to the surface controller 114 to change settings, for example, of pump speed (motor speed), flow rate, valves, chokes, actuators, and so forth. The adjustment module 332 may also instruct the surface controller 114 to perform a system reboot, an equipment restart, or change a start sequence. A control adjustment command from the adjustment module 332 may be preordained in the flight plan 316 from a human or computer source at a base station or surveillance center that originated the flight plan 316. On the other hand, the control adjustment command may be autonomously generated by the diagnostics engine 328, for example, as based on the collected well data 326, now onboard.

[0035] Likewise, a calibration module 334 may bring preordained calibration instructions from a surveillance center, or may simply provide routine tripping of equipment calibration for a calibration controller that is already built into the surface controller 114.

[0036] An update module 336 may be included in the servicing module 330 so that the UAV 102 can deliver software and firmware updates from factory or from the surveillance center to the surface controller 114 of the well 100.

[0037] In an implementation, a troubleshooting module 338 may be included in the servicing module 330 to run diagnostic algorithms in dialogue with the surface controller 114. The troubleshooting module 338 may work in conjunction with a repair module 340 to effect actual repairs that can be performed by resets and adjustments without hands-on intervention of a human worker. Whereas the diagnostics engine 328 sorts through and analyzes historical well data 326 as uploaded by the surface controller 114 to determine if servicing is desirable, the troubleshooting module 338 may query the surface controller 114 to generate new sensor data or run test sequences. The troubleshooting module 338 may add the new sensor data and test results to the well data 326 for further processing at a surveillance center, if an error or fault cannot be solved by the repair module 340. A hardware check module 342 may also add to the stored well data 326, a list of hardware items in the well 100, production tools, monitoring tools, gauges, or ESP string 104 that are at variance with operating thresholds or otherwise tagged by the surface controller 114 for checking or replacement, or to be monitored more carefully in the future by a human worker.

[0038] Fig. 4 shows an example of the surface controller 114 of Fig. 1 , in greater detail. The illustrated example surface controller 114 is just one example, for the sake of description. Other configurations may also be used, with variations in the components. The illustrated components are not required to be in one physical module, but may be distributed according to implementation.

[0039] The example surface controller 114 includes a well operations module 402 capable of recording sensor data from the surface, the well 100, production tools, monitoring equipment, and ESP string 104 and controlling hardware of the well 100, such as motor 106 and pump 108, valves, chokes, actuators, and so forth.

[0040] A UAV dialogue module 404 manages communications with a UAV 102 flying overhead, including communications in play for the other components of the example surface controller 114 via a transceiver, such as a WiFi module 406.

[0041 ] A sensor data uploader 408 transmits well history and sensor data, live or stored, to the airborne controller 118 of the UAV 102 as requested. A remote adjustment module 410 receives signals from the UAV 102 to modify settings and operations of the well 100, production tools, monitoring equipment, ESP string 104, etc. A remote calibration module 412 receives instructions, triggering, and/or calibration standards from the calibration module 334 of the servicing module 330 of the UAV 102 to recalibrate one or more components of the local equipment, ESP string 104, or surface controller 114, etc. A software updater 416 receives a signal from the update module 336 of the airborne controller 118 to update software or firmware of the surface controller 114 or other programmable components of the production equipment, monitoring devices, ESP string 104, sensors 112, or well 100. [0042] A remote troubleshooting module 418 and a remote repair module 420 implement troubleshooting and repair of problems and faults via dialogue with the servicing module 330 of the UAV 102.

[0043] Fig. 5 shows an example UAV well surveillance system 500. The example UAV 102, including airborne controller 118, is stationed during non- flying times at a UAV base station 502. The base station has a wired or wireless connection to the UAV 102 for uploading flight plan 316, instructions, coordinates, updates, and other information for wells 100, ESP strings 104, production tools, monitoring equipment, gauges, and so forth on the flying route defined in the flight plan 316. The base station 502 also recharges (or refuels) the UAV 102 for a coming mission. The UAV 102 may launch autonomously upon wireless command, or by human or mechanical intervention. Once airborne, the UAV 102 flies to the first well 100 on the route, and to subsequence wells 504 & 506. Each well has a wireless communications channel, such as a local WiFi network 116. The UAV 102 completes the route and returns to the base station 502 (or to another base station), and uploads well data 326 collected from the various wells 100 & 504 & 506. The well data 326 may include sensor data, production and flow history, error messages, verification of software and firmware updates, calibration records, lists of hardware to check, and a record of interventions taken by the UAV 102 when connected to the WiFi network 116 of each well 100 & 504 & 506. The base station 502 may be communicatively coupled with a surveillance center 508 via the Internet 510 or other network. The surveillance center 508 processes the well data 326 provided by the UAV 102 through the base station 502, and may generate a new flight plan 316 and well servicing interventions to be uploaded to the UAV 102 though the base station 502 for a subsequent mission.

[0044] Surveillance centers 508 are designed to conduct routine surveillance on reservoirs, wells, facilities, and subsea systems and may be staffed by surveillance engineers, control-room operators, and information technology analysts. Centralizing routine surveillance enables cross-asset sharing of top surveillance techniques, develops staff surveillance competence, and allows asset-focused engineers to ensure project delivery. A surveillance center 508 enables event identification, surveillance execution, and systematic history documentation. Events and analyses are stored in a searchable online database to facilitate analysis of future events.

[0045] Due to cost and location, even though continuous monitoring of wells 100 through a surveillance center 508 is advantageous, monitoring operations of many land-based wells 100 by a surveillance center 508 are limited because the monitoring necessitates transporting a human field technician to the well site, verifying acquisition status of data collected, and then reporting results to a central office. Because a field technician must physically visit the site and the number of technicians may be limited, a malfunctioning device, such as a component of the ESP string 104, may not be detected for several weeks using this conventional approach. [0046] In an implementation, the base station 502 and surveillance center 508 utilize a standard platform, such as OPC Unified Architecture (UA). Well sensors 112 and actuators may be integrated into a communication network, with a communication protocol allowing implementation on both embedded and non-embedded systems. The example well system 100 including communications and well-servicing via UAV 102 provides end-to-end communication of status and control commands between rig subsystems and the UAVs 102. The communication protocols may include provisions for buffering, storing, and forwarding to a better address the intermittent connectivity that may be presented from either episodic or intermittent mobile- UAV-based networks or temporary connectivity drops from permanent or semipermanent fixed aerial repeaters.

[0047] In an implementation, the UAV 102 is deployed from the UAV base station 502. The UAV base station 502 is configured with access to an Internet network 510 or satellite connection. A software application, such as AVOCET or another petroleum well production software platform, may have multiple wells registered, and each registered well is assigned a unique identifier and corresponding GPS location. The base station software platform, surface controller 114, and airborne controller 118 can allow a user to choose a monitoring routine, such as specifying which wells should be checked and at which specified interval, such as daily, weekly, or monthly. The monitoring routine may depend on the specifics of each particular well 100. In an implementation, the monitoring routine and flight plan 316 can be programmed from a remote central surveillance system 508 via the Internet 510 or through a satellite data link.

[0048] In an example, at a pre-programmed time, the UAV 102 leaves the base station 502 and flies to a first well location. Once the UAV 102 is within a pre-defined distance of the well 100 or the connection module 310 can detect the well 100 using the wireless network 116 of the well 100, the UAV 102 establishes wireless communication with the well surface controller 114. Several types off well surface controllers 114 may be used.

[0049] In an embodiment, the well surface controller 114 communicates with the UAV 102 via a camera capable of reading data from a controller display system, either directly or using quick response (QR) code or other type of matrix barcode. In an implementation, the UAV 102 can be humanly remote controlled by a human.

[0050] The surface controller 114 can include or be integrated or retrofitted into production and monitoring equipment, for example, ESP controllers such as UNICONN and INSTRUCT systems (Schlumberger Technology Corporation, Houston TX). Such example ESP controllers may run embedded software on multiple control cards. In some embodiments, data can be collected directly from downhole sensors 112. The sensor data may correspond to the latest period in which data has not yet been collected (day / week / month). However, the sensor data and other information to be retrieved are not limited to a single period or to the latest period. [0051] Data from the downhole sensors 112, such as intake and discharge pressure, temperature, and vibration of single or multi-components are collected. The data may be highly sampled or sparsely sampled.

[0052] Collected data may be uploaded to a surveillance center 508 that uses a system such as the LIFTWATCHER (Schlumberger Technology Corporation, Houston, TX). The LIFTWATCHER system may utilize surveillance engineers to monitor alarms and alerts. The example UAV surveillance system 500 allows data to be collected from wells 100 without SCADA systems and uploaded into the LIFTWATCHER system.

[0053] Fig. 6 shows an example airship as the UAV 102. A tethered or mobile dirigible or airship in the role of the UAV 102 can be utilized to extend or establishing wireless radio frequency (RF) communication link(s) across a field of wells 100 & 504 & 506. The airborne controller 118 on the airship UAV 102 may serve as a relay of real time or stored data from a well 100. When the airship can communicate with the multiple wireless networks of both a well 100 and a remote data hub to receive the data, such as a surveillance center 508, then the need for a flight plan 316 to fly between remote wells 100 & 504 & 506 may be eliminated.

[0054] Fig. 7 shows high-altitude UAVs 102, deployed to enhance a field of communications between the wireless networks 116 of wells 100, base stations 506, and surveillance centers 508. A high-altitude balloon UAV 102 or a high-altitude, persistent drone UAV 102 may each carry an instance of the example airborne controller 118. A hierarchy of UAV's may also be deployed, in which local drone UAVs 102 fly between wells 100 & 504 & 506, and communicate with a UAV 102 that manages a team of multiple UAVs 102. The higher rank UAV 102 may have a higher altitude that is more accessible to local wells 100 and localized UAVs 102, and/or may carry a more powerful radio frequency transceiver that can send and receive RF signals at greater distances than the lower-flying UAVs 102.

[0055] Fig. 8 is an example method of wireless communication with a well system via one or more UAVs. The operations are shown as individual blocks.

[0056] At block 802, data associated with a well is generated at a location of the well.

[0057] At block 804, an unmanned aerial vehicle (UAV) is deployed, including at least a wireless data receiver and a wireless data transmitter.

[0058] At block 806, the data is transferred from the location of the well to a data hub at a second location via the UAV.

[0059] Fig. 9 shows an example method 900 of well surveillance and servicing via an UAV. The operations are shown as individual blocks. The example method 900 may be performed by hardware, such as the example UAV surveillance system 500.

[0060] At block 902, an unmanned aerial vehicle (UAV) is programmed with a well monitoring routine.

[0061 ] At block 904, the UAV is instructed to leave a base and fly to a well along a route. [0062] At block 906, communication is established between the flying UAV and the well.

[0063] At block 908, the UAV collects well parameters, including equipment parameters, ESP parameters, sensor data, surface data, and so forth from the well. The UAV may then fly to the next well and establish communication with the subsequent well, as at block 906.

[0064] At block 910, the UAV returns to the base and communicatively connects with the base application software.

[0065] At block 912, the well parameters, ESP parameters, sensor data, equipment data, and so forth are downloaded from the UAV to the base application software.

Conclusion

[0066] Although a few embodiments of the disclosure 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 this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.