Tool for Use in Well Tubing and Method of Using Same

Technical Field

Some described examples generally relate to downhole tools, and in particular, to a tool for use in well tubing and a method of using the same.

Background

During well drilling, completion and production, one or more tools may be used to monitor the status of the well. The tools may include gauges that have sensors to detect parameters at the well such as pressure, temperature, strain, force, conductivity, etc.

Such tools may be deployed downhole in the well. In order to communicate the detected parameter data to the surface and/or to receive signals from the surface, communication/other modules may additionally be present in the tool. Exemplary communication modules include transmitters, receivers and transceivers. These modules and the gauges may require power from uphole. Power may be supplied to the downhole tool through wired connection or wirelessly. Wired communications are through a guided transmission medium, such as a wire, other metallic structure or a material having high electromagnetic (EM) conductivity relative to a surrounding medium. Wired communication methods may utilize e-lines, slicklines, fibre optic cabling, etc. Wireless communications are communications that are not through a guided transmission medium. Wireless communications may, for example, be through air, water, ground (or formation) or another medium that has substantially isotropic EM conductivity. Wireless communication methods may utilize electromagnetic technology, acoustic technology and/or pressure wave technology.

The gauges and communication modules described may receive power via wired or wireless communications, or power may be available downhole via one or more batteries.

As previously stated the tools may be deployed downhole. Specifically, the tools may be deployed internally within well tubing, such as on a centralizer, and/or externally outside of the tubing deployed inside casing. The tubing is generally composed of multiple pipes linked together by connections.

The tubing has a fixed maximum internal diameter determined by one or more of limits dictated by regulatory agencies, the geological properties of the formation in which the well is drilled and/or the fluid being extracted from the formation. This maximum internal diameter limits the diameter of deployed downhole tools. Downhole tools deployed internally within the tubing are limited by the maximum internal diameter of the tubing and must also minimize fluid (production or otherwise) flow restriction. Downhole tools deployed externally are limited by the size of the wellbore. For example, the applicant supplies a tool under the name CaTS™ that has maximum outer diameter of 1.6875 inches or 2.125 inches (4.286 cm or 5.398 cm, respectively) depending on the application.

Given the size limits of these downhole tools, any batteries included in the tools must be arranged end-end-end to keep the tool within the noted maximum diameters. However, there is a practical limit on the overall length of the tool, accordingly, there is a limit on the number of batteries in the tool and therefore the available battery supplied power.

Furthermore, downhole tools may only have space for a single sensor and therefore can only detect a single parameter. If there is an operational need to have multiple sensors, multiple tools must be used and deployed end-to-end which is similarly limited by the practical limit on the overall length of the tool. Longer tool strings are difficult and time consuming to deploy and install. Furthermore, the internal configuration of each tool becomes more complex due to the requirement to have a low direct current (DC) resistance signal path for the entire length of the tool string.

This background serves only to set a scene to allow a person skilled in the art to better appreciate the following description. Therefore, none of the above discussion should necessarily be taken as an acknowledgement that that discussion is part of the state of the art or is common general knowledge. One or more aspects/embodiments of the invention may or may not address one or more of the background issues.

Summary In some or more examples, a tool for use in well tubing is provided. The tool provides a greater volume to store more batteries and gauges than conventional tools.

In some or more examples, the tool substantially spans a diameter of well tubing. In other words, the tool substantially fills the internal volume of well tubing.

By substantially spanning a diameter of well tubing or substantially filling the internal volume of well tubing, the tool provides a greater volume to store more batteries and gauges than conventional tools.

Conventional tools are generally affixed to centralizers within tubing or clamped externally to the tubing which is deployed inside casing. If the tool is within tubing, its diameter must be minimized in order to minimize fluid flow restriction. If the tool is external to the tubing, its diameter must be minimized such that the wellbore diameter does need to be increased. As will be appreciated, the resulting physical constraints of this minimal diameter, generally in the order of 1.6875 inches (4.2863 cm) or 2.1250 inches (5.3975 cm), restrict the number of components within the tool.

Specifically, this limited diameter results in an end-to-end arrangement of batteries and gauges of the tool as batteries and gauges may not be radially adjacent due to the limited diameter. The practical limit on the overall length of the tool limits the number of batteries and gauges that may therefore form part of the tool. The limited number of batteries provide only limited power to the gauges that may additional include communication or other modules in the tool. This results in a reduced number of gauges being used in the tool. Furthermore, the spent batteries will need to be replaced more frequently or the entire tool may require replacement.

However, by substantially filling the internal volume of well tubing, the tool does not permit fluid flow through the well tubing. In some or more examples, the tool is generally solid, not hollow. Accordingly, the well tubing is suitable for abandonment applications whether on-shore or offshore, and in other such inactive wells. In some or more examples, the tool is generally cylindrical. In some or more examples, the tool has a generally uniform radius extending from a central point thereof, and accordingly a generally uniform diameter along the length of the cylindrical tool.

In some or more examples, the tool further comprises a battery cluster comprising one or more batteries and associated conductors.

In some or more examples, the tool comprises multiple battery clusters. In some or more examples, the battery clusters are arranged end-to-end. The battery clusters are arranged end-to-end along the length of the tool.

In some or more examples, the battery cluster comprises slots. Each slot can accommodate a single battery or conductor. In some or more examples, all of the slots are occupied by batteries and conductors. In some or more examples, not all of the slot are occupied.

In some or more examples, the slots comprise at least one of a battery slot configured to accommodate a single battery and a conductor slot configured to accommodate a conductor.

The batteries are configured to provide power to the components of the tool. In some or more examples, the batteries are off-the-shelf batteries. In some or more examples, the batteries are one of high rate and moderate rate. In some or more examples, the batteries are C or D cell batteries. In some or more examples, the batteries are battery cells.

The conductors are configured to transfer communications signals. In some or more examples, the conductors are copper.

In some or more examples, the batteries and conductors are geometrically arranged in the battery cluster.

In some or more examples, there are an equal number of batteries and conductors in the battery cluster. In some or more examples, there are six (6) batteries in a single cluster and six (6) conductors in a single cluster.

In some or more examples, there are seven (7) batteries in a single cluster and seven (7) conductors in a single cluster.

In some or more examples, the battery cluster further comprises a slot for a wiring harness. In some or more examples, the wiring harness comprises wires. In some or more examples, the wiring harness is centrally located within the battery cluster. In other words, the wiring harness is located such that it longitudinally extends along the radial central axis of the battery cluster. The wiring harness is configured to interconnect the elements of the battery cluster such as batteries and conductors. In some or more examples, the wiring harness is configured to interconnect longitudinally adjacent clusters, in other words clusters that arranged end-to-end.

In some or more examples, the batteries are radially adjacent within the battery cluster. The batteries are therefore not end-to-end within the battery cluster, but are instead adjacent (to each other and/or to conductors) and arranged radially in the battery cluster. Thus, more batteries may be stored in a single battery cluster within a length of the tool as the batteries are not end-to-end. In this embodiment, the battery cluster is generally cylindrical. The batteries are arranged radially within the cylindrical battery cluster. In some or more examples, the batteries are arranged radially from a central point of the cylindrical battery cluster.

In some or more examples, the number of batteries and resistance of the conductors are optimized. In some or more examples, optimizing comprising maximizing the number of batteries for a minimum resistance of the conductors.

In some or more examples, the number of batteries is maximized and resistance of the conductors is minimized. Maximizing the number of batteries maximizes the power available downhole. Minimizing the resistance of the conductors minimizes transmission losses through the conductors.

In some or more examples, the tool further comprises an electronics cluster. In some or more examples, the battery cluster is configured to provide power to the electronics cluster. One or more battery clusters may power one or more electronics clusters. In particular, multiple battery clusters may be connected together to power one or more electronics clusters.

Individual battery or electronics clusters may be removed from the tool and replaced/repaired while remaining battery and/or electronics clusters remain in the tool. For example, battery clusters with spent batteries may be replaced with battery clusters with batteries that still have power. In this manner, the entire tool does not need to be completely replaced with batteries in a single battery cluster are spent.

In some or more examples, the battery cluster and the electronics cluster are arranged end-to-end. As will be appreciated, multiple battery and/or electronics clusters may be arranged end-to-end.

In some or more examples, the electronics cluster comprises at least one of a gauge and a module. In some or more examples, the electronics cluster comprises at least one gauge and at least one module. In some or more examples, the gauge and/or module are radially adjacent. In this embodiment, the electronics cluster is generally cylindrical. The gauge and/or module is arranged radially within the cylindrical electronics cluster. In some or more examples, the gauge and/or module is arranged radially from a central point of the cylindrical electronics cluster.

The gauge and module are therefore not end-to-end within the electronics cluster, but are instead adjacent to other gauges and/or modules, and arranged radially in the electronics cluster. Thus, more gauges and/or modules may be stored in a single electronics cluster within a length of the tool as the gauge and module are not end-to- end. In this embodiment, the electronics cluster is generally cylindrical. The gauges and/or modules are arranged radially within the cylindrical electronics cluster. In some or more examples, the gauges and/or modules are arranged radially from a central point of the cylindrical electronics cluster.

In some or more examples, the gauge comprises a sensor. The sensor is configured to sense, measure or detect parameters comprising at least one of pressure, temperature, strain, force, electrical conductivity or resistance, etc. In some or more examples, the gauge comprises multiple sensors. In some or more examples, the module is a communication module. The communication module is configured to communicate with one or more gauges. Specifically, the communication module is configured to receive one or more signals from a gauge for transmission. In some or more examples, the signals are transmitted to a remote location, such as a location uphole from the tool. In some or more examples, the signals are parameters that are sensed, measured or detected by a gauge. In addition or alternately, the communication module is configured to receive signals for transmission to the gauge. Specifically, the communication module is configured to receive control signals from a remote location, such as a location uphole from the tool. The communication module is configured to transmit the control signals to one or more gauges.

In some or more examples, the communication module is configured to transfer communication signals via the battery cluster. In some or more examples, communications signals are transferred via one or more conductors of the battery cluster. The communication module and conductors form a direct current (DC) resistance (DCR) path for communication signals.

In some or more examples, the communication module comprises at least one of a receiver, transmitter and transceiver. In some or more examples, the communication module employs wired and/or wireless communication methods. Wired communication methods are through a guided transmission medium, such as a wire, other metallic structure or a material having high electromagnetic (EM) conductivity relative to a surrounding medium. Wired communication methods may utilize e-lines, slicklines, fibre optic cabling, etc. Wireless communication methods are not through a guided transmission medium. Wireless communication methods are through air, water, ground (or formation) or another medium that has substantially isotropic EM conductivity. In some or more examples, wireless communication methods utilize electromagnetic technology, acoustic technology and/or pressure wave technology.

In some or more examples, the electronics cluster further comprises a slot for a wiring harness. In some or more examples, the wiring harness is centrally located within the electronics cluster. In some or more examples, the wiring harness is centrally located in the cylindrical electronics cluster. In other words, the wiring harness is located such that it longitudinally extends along the radial central axis of the electronics cluster. The wiring harness is configured to interconnect the elements of the electronics cluster such as gauges and modules. In some or more examples, the wiring harness is configured to interconnect longitudinally adjacent clusters, in other words clusters that are arranged end-to-end.

In some or more examples, the tool is configured to be concentric to a wellbore. The tool is configured to be positioned within a wellbore. Once positioned within the wellbore, the tool is concentric to the wellbore or within the wellbore.

In some or more examples, the tool is configured for use in an abandoned well. In some or more examples, the abandoned well is an appraisal well. At the end of lifecycle of a well, or at the end of an appraisal process, steps may be taken to permanently abandon a well. The abandoned well is on-shore or offshore. As no fluid flow is present in an abandoned well, the tool does not restrict fluid flow in the well.

In some or more examples, the tool is configured to use in a sidetrack of a well. A sidetrack is a secondary wellbore drilled away from the original well. It is possible to have multiple sidetracks, each of which may have been drilled for different reasons. In some or more examples, the sidetrack is unused. Specifically, the sidetrack is unused for collecting production fluid. Use of the tool in a sidetrack that is not used for collecting production fluid ensures that the tool does not restrict the flow and/or collection of production fluid.

In some or more examples, the tool is pressure enclosed. In some or more examples, each individual cluster is pressure enclosed. In some or more examples, the entire tool is pressure enclosed. Pressure enclosing the cluster and/or tool ensures fluid (gas or liquid) cannot enter the cluster and/or tool, and effect including cause damage to the various elements of the cluster and tool.

In some or more examples, the tool is configured to allow for direct electrical connection to one or more adjacent tools. In some or more examples, adjacent tool are arranged longitudinally end-to-end to the tool. In some or more examples, one tool comprises only battery clusters, while an adjacent tool comprises at least one electronics cluster. Power and/or measured parameters may be transferred between adjacent tools via the electrical connection between these adjacent tools.

In some or more examples, the tool further comprises an end cap.

In some or more examples, the end cap provides electrical connection. In some or more examples, the electrical connection is between adjacent tools. In some or more examples, the electrical connection is to components within the tool.

In some or more examples, a diameter of the tool is approximately 5.5 inches (14.0 cm).

In some or more examples, a system comprising the described tool and well tubing is provided. In some or more examples, the tool substantially spanning a diameter of the well tubing.

In some or more examples, a tool for use in well tubing is provided. In some or more examples, the tool extends longitudinally in well tubing and has radially adjacent batteries.

As previously stated, conventional tools are generally affixed to centralizers within tubing or clamped externally to the tubing which is deployed inside casing. If the tool is within tubing, its diameter must be minimized in order to minimize fluid flow restriction. If the tool is external to the tubing, its diameter must be minimized such that the wellbore diameter does need to be increased. As will be appreciated, the resulting physical constraints of this minimal diameter, generally in the order of 1.6875 inches (4.2863 cm) or 2.1250 inches (5.3975 cm), restrict the number of components within the tool.

Specifically, this limited diameter results in an end-to-end arrangement of batteries and gauges of the tool as batteries and gauges may not be radially adjacent due to the limited diameter. The practical limit on the overall length of the tool limits the number of batteries and gauges that may therefore form part of the tool. The limited number of batteries provide only limited power to the gauges that may additionally include communication or other modules in the tool. This results in a reduced number of gauges being used in the tool. Furthermore, the spent batteries will need to be replaced more frequently or the entire tool may require replacement.

In contrast, the described tool has radially adjacent batteries. As the batteries are radially adjacent, more batteries may fit within the tool in total and per unit length compared to conventional end-to-end arrangements of batteries in conventional tools.

In some or more examples, the tool is cylindrical. In some or more examples, the tool has a generally uniform radius extending from a central point thereof, and accordingly a generally uniform diameter along the length of the cylindrical tool.

In some or more examples, the batteries are within a battery cluster within the tool. The batteries are not end-to-end within the battery cluster, but are instead adjacent and arranged radially in the battery cluster. Thus, more batteries may be stored in a single battery cluster within a length of the tool as the batteries are not end-to-end. In this embodiment, the battery cluster is generally cylindrical. The batteries are arranged radially within the cylindrical battery cluster. In some or more examples, the batteries are arranged radially from a central point of the cylindrical battery cluster.

In some or more examples, the tool comprises multiple battery clusters. In some or more examples, the battery clusters are arranged end-to-end. The battery clusters are arranged end-to-end along the length of the tool.

In some or more examples, the battery clusters comprises batteries and associated conductors. In some or more examples, the battery cluster comprises. Each slot can accommodate a single battery or conductor. In some or more examples, all of the slots are occupied by batteries and conductors. In some or more examples, not all of the slots are occupied.

In some or more examples, the slots comprise at least one of a battery slot configured to accommodate a single battery and a conductor slot configured to accommodate a conductor.

The batteries are configured to provide power to the components of the tool. In some or more examples, the batteries are off-the-shelf batteries. In some or more examples, the batteries are one of high rate and moderate rate. In some or more examples, the batteries are C or D cell batteries. In some or more examples, the batteries are battery cells.

The conductors are configured to transfer communications signals. In some or more examples, the conductors are copper.

In some or more examples, the batteries and conductors are geometrically arranged in the battery cluster.

In some or more examples, there are an equal number of batteries and conductors in the battery cluster.

In some or more examples, there are six (6) batteries in a single cluster and six (6) conductors in a single cluster.

In some or more examples, there are seven (7) batteries in a single cluster and seven (7) conductors in a single cluster.

In some or more examples, the battery cluster further comprises a slot for a wiring harness. In some or more examples, the wiring harness comprises wires. In some or more examples, the wiring harness is centrally located within the battery cluster. In other words, the wiring harness is located such that it longitudinally extends along the radial central axis of the battery cluster. The wiring harness is configured to interconnect the elements of the battery cluster such as batteries and conductors. In some or more examples, the wiring harness is configured to interconnect longitudinally adjacent clusters, in other words clusters that arranged end-to-end.

In some or more examples, the number of batteries and resistance of the conductors are optimized. In some or more examples, optimizing comprises maximizing the number of batteries for a minimum resistance of the conductors.

In some or more examples, the number of batteries is maximized and resistance of the conductors is minimized. Maximizing the number of batteries maximizes the power available downhole. Minimizing the resistance of the conductors minimizes transmission losses through the conductors. In some or more examples, the electronics cluster comprises at least one of a gauge and a communications module. In some or more examples, the battery cluster is configured to provide power to the electronics cluster. One or more battery clusters may power one or more electronics clusters. In particular, multiple battery clusters may be connected together to power one or more electronics clusters.

Individual battery or electronics clusters may be removed from the tool and replaced/repaired while remaining battery and/or electronics clusters remain in the tool. For example, battery clusters with spent batteries may be replaced with battery clusters with batteries that still have power. In this manner, the entire tool does not need to be completely replaced when batteries in a single battery cluster are spent.

In some or more examples, the battery cluster and the electronics cluster are arranged end-to-end. As will be appreciated, multiple battery and/or electronics clusters may be arranged end-to-end.

In some or more examples, the electronics clusters comprises at least one gauge and at least one communications module. In some or more examples, the gauge and the module are radially adjacent.

In some or more examples, the tool comprises at least one battery cluster and at least one electronics cluster. In some or more examples, the battery cluster and the electronics cluster are arranged end-to-end within the tool.

The gauge and module are therefore not end-to-end within the electronics cluster, but are instead adjacent to other gauges and/or modules, and arranged radially in the electronics cluster. Thus, more gauges and/or modules may be stored in a single electronics cluster within a length of the tool as the gauge and module are not end-to- end. In this embodiment, the electronics cluster is generally cylindrical. The gauges and/or modules are arranged radially within the cylindrical electronics cluster. In some or more examples, the gauges and/or modules are arranged radially from a central point of the cylindrical electronics cluster. In some or more examples, the gauge comprises a sensor. The sensor is configured to sense, measure or detect parameters comprising at least one of pressure, temperature, strain, force, electrical conductivity or resistance, etc. In some or more examples, the gauge comprises multiple sensors.

In some or more examples, the communication module is configured to communicate with one or more gauges. Specifically, the communication module is configured to receive one or more signals from a gauge for transmission. In some or more examples, the signals are transmitted to a remote location, such as a location uphole from the tool. In some or more examples, the signals are parameters that are sensed, measured or detected by a gauge. In addition or alternately, the communication module is configured to receive signals for transmission to the gauge. Specifically, the communication module is configured to receive control signals from a remote location, such as a location uphole from the tool. The communication module is configured to transmit the control signals to one or more gauges.

In some or more examples, the communication module is configured to transfer communication signals via the battery cluster. In some or more examples, communications signals are transferred via one or more conductors of the battery cluster. The communication module and conductors form a direct current (DC) resistance (DCR) path for communication signals.

In some or more examples, the communication module comprises at least one of a receiver, transmitter and transceiver. In some or more examples, the communication module employs wired and/or wireless communication methods. Wired communication methods are through a guided transmission medium, such as a wire, other metallic structure or a material having high electromagnetic (EM) conductivity relative to a surrounding medium. Wired communication methods may utilize e-lines, slicklines, fibre optic cabling, etc. Wireless communication methods are not through a guided transmission medium. Wireless communication methods are through air, water, ground (or formation) or another medium that has substantially isotropic EM conductivity. In some or more examples, wireless communication methods utilize electromagnetic technology, acoustic technology and/or pressure wave technology. In some or more examples, the electronics cluster further comprises a slot for a wiring harness. In some or more examples, the wiring harness is centrally located within the electronics cluster. In some or more examples, the wiring harness is centrally located in the cylindrical electronics cluster. In other words, the wiring harness is located such that it longitudinally extends along the radial central axis of the electronics cluster. The wiring harness is configured to interconnect the elements of the electronics cluster such as gauges and modules. In some or more examples, the wiring harness is configured to interconnect longitudinally adjacent clusters, in other words clusters that are arranged end-to-end.

In some or more examples, the tool is configured to be concentric to a wellbore. The tool is configured to be positioned within a wellbore. Once positioned within the wellbore, the tool is concentric to the wellbore or within the wellbore.

In some or more examples, the tool is configured for use in an abandoned well. In some or more examples, the abandoned well is an appraisal well. At the end of lifecycle of a well, or at the end of an appraisal process, steps may be taken to permanently abandon a well. The abandoned well is on-shore or offshore. As no fluid flow is present in an abandoned well, the tool does not restrict fluid flow in the well.

In some or more examples, the tool is configured to use in a sidetrack of a well. A sidetrack is a secondary wellbore drilled away from the original well. It is possible to have multiple sidetracks, each of which may have been drilled for different reasons. In some or more examples, the sidetrack is unused. Specifically, the sidetrack is unused for collecting production fluid. Use of the tool in a sidetrack that is not used for collecting production fluid ensures that the tool does not restrict the flow and/or collection of production fluid.

In some or more examples, the tool is pressure enclosed. In some or more examples, each individual cluster is pressure enclosed. In some or more examples, the entire tool is pressure enclosed. Pressure enclosing the cluster and/or tool ensures fluid (gas or liquid) cannot enter the cluster and/or tool, and effect including cause damage to the various elements of the cluster and tool. In some or more examples, the tool is configured to allow for direct electrical connection to one or more adjacent tools. In some or more examples, adjacent tool are arranged longitudinally end-to-end to the tool. In some or more examples, one tool comprises only battery clusters, while an adjacent tool comprises at least one electronics cluster. Power and/or measured parameters may be transferred between adjacent tools via the electrical connection between these adjacent tools.

In some or more examples, the tool further comprises an end cap.

In some or more examples, the end cap provides electrical connection. In some or more examples, the electrical connection is between adjacent tools. In some or more examples, the electrical connection is to components within the tool.

In some or more examples, a diameter of the tool is approximately 5.5 inches (14.0 cm).

In some examples, a method of using a tool in well tubing is provided. The method provides for communication of data between adjacent tools.

In some or more examples, the tool substantially spans a diameter of well tubing, and the method comprises transferring a signal from the tool to another tool.

In some or more examples, the tool receives data or information from a location remote of the tool. The data is then communicated to the other tool. Thus, the other tool does not have to have hardware to receive the data. The design, size and hardware of the other tool is therefore simplified which reduces costs. In some or more examples, the tool transfers power to the other tool. The other tool may therefore have reduced power capacity that simplifies the design, hardware and size of the other tool, and reduces costs.

In some or more examples, the signal is one of a power and a data signal. In some or more examples, transferring the signal comprises transferring a power signal from a battery cluster of the tool to the other tool. In some or more examples, transferring the power signal comprises transferring power from a battery in the battery cluster via a conductor.

In some or more examples, transferring the signal comprises transferring a data signal from an electronics cluster of the tool to the other tool. In some or more examples, transferring the data signal comprises transferring data from a gauge and/or a communication module of the electronics cluster.

In some or more examples, transferring the signal comprises directly transferring the signal to the other tool. In some or more examples, transferring the signal comprises transferring the signal through an end cap of the tool. In some or more examples, the signal is transferred via a wiring harness and the end cap of the tool to the other tool.

In some or more examples, the tool comprises the previously described tool.

In some or more examples, the method further comprises transferring a signal from the other tool to the tool. In some or more examples, the signal is a data signal collected, measured or detected by the other tool. In some or more examples, the tool is configured to communicate the signal from the other tool to a remote location. In some or more examples, the tool is configured to communicate the signal via a communication module of an electronics cluster of the tool.

As the other tool is not transmitting the signal to a remote location, the other tool does not have communication hardware. The hardware of the other tool is therefore simplified which reduces costs.

Aspects of the inventions described may include one or more examples, embodiments or features in isolation or in various combinations whether or not specifically stated (including claimed) in that combination or in isolation.

Brief Description of the Figures

A description is now given, by way of example only, with reference to the accompanying drawings, in which: Figure 1 A is a simplified representation of a well;

Figure 1B is a simplified representation of the well of Figure 1A during abandonment; Figure 1C is a simplified representation of the well of Figure 1A in an abandoned state; Figure 2 is a simplified representation of the well of Figure 1C including a tool in accordance with an aspect of the disclosure;

Figure 3 is a side elevation view of the tool of Figure 2;

Figure 4 is a cross-sectional view of a battery cluster of the tool along section lines A-A of Figure 3; and

Figure 5 is a cross-sectional view of an electronics cluster of the tool along section lines B-B of Figure 3.

Description of Specific Embodiments

The foregoing summary, as well as the following detailed description of certain embodiments will be better understood when read in conjunction with the accompanying drawings. As will be appreciated, like reference characters are used to refer to like elements throughout the description and drawings. As used herein, an element or feature recited in the singular and preceded by the word "a" or "an" should be understood as not necessarily excluding a plural of the elements or features. Further, references to "one example" or “one embodiment” are not intended to be interpreted as excluding the existence of additional examples or embodiments that also incorporate the recited elements or features of that one example or one embodiment. Moreover, unless explicitly stated to the contrary, examples or embodiments "comprising", "having" or “including” an element or feature or a plurality of elements or features having a particular property might further include additional elements or features not having that particular property. Also, it will be appreciated that the terms “comprises”, “has” and “includes” mean “including but not limited to” and the terms “comprising”, “having” and “including” have equivalent meanings.

As used herein, the term “and/or” can include any and all combinations of one or more of the associated listed elements or features.

It will be understood that when an element or feature is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc. another element or feature, that element or feature can be directly on, attached to, connected to, coupled with or contacting the other element or feature or intervening elements may also be present. In contrast, when an element or feature is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element of feature, there are no intervening elements or features present.

It will be understood that spatially relative terms, such as “under”, “below”, “lower”, “over”, “above”, “upper”, “front”, “back” and the like, may be used herein for ease of describing the relationship of an element or feature to another element or feature as depicted in the figures. The spatially relative terms can however, encompass different orientations in use or operation in addition to the orientation depicted in the figures.

Reference herein to “example” means that one or more feature, structure, element, component, characteristic and/or operational step described in connection with the example is included in at least one embodiment and or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example.

Reference herein to “configured” denotes an actual state of configuration that fundamentally ties the element or feature to the physical characteristics of the element or feature preceding the phrase “configured to”.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of lower-numbered item (e.g., a “first” item) and/or a higher-numbered item (e.g., a “third” item).

As used herein, the terms “approximately” and “about” represent an amount close to the stated amount that still performs the desired function or achieves the desired result. For example, the terms “approximately” and “about” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, or within less than 0.01% of the stated amount.

Some of the following examples have been described specifically in relation to well infrastructure relating to oil and gas production, or the like, but of course the systems and methods may be used with other well structures. Similarly, while in the following example an offshore well structure is described, nevertheless the same systems and methods may be used onshore, as will be appreciated.

Turning now to Figure 1A, a simplified representation of a well is shown and is generally identified by reference numeral 100. In this embodiment, the well 100 is offshore. In this embodiment, the well 100 is an appraisal well.

The well 100 comprises a well structure 102 and a wellhead 106, wet tree or the like, at a production platform 108. In other embodiments, the wellhead 106 may be provided at the mudline 104. The metallic well structure 102 extends from the surface, in this case the seabed or mudline 104, to a subterranean formation. In this embodiment, the well structure 102 includes at least one of a conductor, casing and other tubing used to recover product from the formation. A lower section 110 of the well 100 is open hole, in that there is no well structure positioned within the well in this section. In this embodiment, the well structure 102 extends generally to the seabed 104.

Turning to Figure 1B, when the well 100 is abandoned, a first cement plug 112 is typically formed at or just above the open hole section 110 of the well 100. In this embodiment, the first cement plug 112 is formed by pumping wet cement into the well 100. Typically, a second cement plug 114 is formed above the first cement plug 112. An intermediate section 116 of the well 100 forms an enclosed space between the first and second plugs 112 and 114, respectively.

Turning to Figure 1C, when the well 100 is in its final abandoned state, the well structure 102 is severed below the seabed or mudline 104.

As previously stated, the well structure 102 includes at least one of a conductor, casing and other tubing used to recover product from the formation. Conventional tools are generally affixed to centralizers within this tubing or clamped to the tubing. The tubing is deployed inside casing. Thus, the tool is clamped to the tubing between the tubing and the casing. If the tool is within tubing, its diameter must be minimized in order to minimize fluid flow restriction within the tubing of the well structure 102. If the tool is external to the tubing, its diameter must be minimized such that the wellbore diameter of the well 100 does need to be increased. As will be appreciated, the resulting physical constraints of this maximum diameter, generally in the order of 1.6875 inches (4.2863 cm) or 2.1250 inches (5.3975 cm), restrict the number of components within the tool. Given this maximum diameter, batteries and gauges of the tool must be arranged longitudinally end-to-end. The practical limit on the overall length of the tool limits the numbers of batteries and gauges that may be arranged longitudinally end-to- end. Accordingly, the tool has limited power storage (batteries), and sensing and transmission capabilities (gauges and communication modules).

In contrast, a tool in accordance with an aspect of the disclosure substantially spans a diameter of well tubing of the well structure 102. Turning now to Figure 2, a simplified representation of the well 100 is shown with a tool in accordance with an aspect of the disclosure generally identified by reference numeral 200 is shown.

In contrast with conventional tools, the tool 200 substantially spans the diameter of the tubing of the well structure 102. As the well 100 is abandoned, there is no need to ensure that the tool 200 does not restrict fluid flow within the well 100. Accordingly, the tool 200 may substantially span the entire diameter of the tubing. In other words, the tool 200 substantially fills the internal volume of the tubing.

As will be appreciated, the tool 200 may be used in other wells where fluid flow is not present such as an unused well, an unused appraisal well and an unused sidetrack of a well. These wells may be offshore or onshore.

The internal volume of the tubing is generally cylindrical in shape. Similarly, the tool 200 is generally cylindrical in shape. In this embodiment, the tool 200 has a generally uniform radius extending radially from a central point thereof. The tool 200 is concentric to the wellbore of the well 200. The tool 200 has a consistent and plain circumference. Accordingly, the tool 200 may be easily deployed within the well 200 and is not restricted when running past existing liner hangers or open hole section 110. As will be appreciated, the tool 200 has a greater diameter than conventional tools. As previously stated, conventional tools have a diameter of approximately 1.6875 inches (4.2863 cm) or 2.1250 inches (5.3975 cm). The tool 200 has a diameter of at least greater than 3.0 inches (7.6 cm) and an approximate maximum diameter of 5.5 inches (14.0 cm).

The tool 200 is positioned within the tubing of the well structure 102. In this embodiment, the tool 200 is held within tubing by one of hangers, clamps, friction fit, setting tools, etc. The tool 200 runs a length of the tubing. The overall longitudinal length of the tool 200 depends on the number of components in the tool 200 as will be described; however, the overall length of the tool 200 is generally between 28 and 30 feet (8.53 m to 9.14 m). The width or diameter of the tool 200 is approximately 5.5 inches (14.0 cm).

Turning now to Figure 3, an elevation view of the tool 200 is shown. The tool 200 comprises an enclosure 202, an end cap 204, a battery cluster 210, an electronics cluster 240 and an isolating joint (not shown). The enclosure 202 is a pressure enclosure that encloses the battery and electronics clusters 210 and 240, respectively, therein. The enclosure 202 prevents ingress and/or egress of fluids into or out of the tool 200.

The isolating joint is configured to control the flow of electrical current and/or electrically isolate sections of the tool 200.

In this embodiment, the tool 200 comprises a single end cap 204 at one longitudinal end of the enclosure 202; however, it will be appreciated that the tool 200 may comprises two end caps 204, one on each longitudinal end of the enclosure 202. The end cap 204 is configured to provide electrical connection. The end cap 204 provides communication signals connection between the components of the tool 200, e.g. the battery cluster 210 and the electronics cluster 240, and tools adjacent (i.e. arranged longitudinally end-to-end) to the tool 200. Specifically, the end cap 204 allows for transfer of communications signals between adjacent tools as will be described. Exemplary adjacent tools includes valves, TCP guns, suspensions devices, etc. as well as other tools 200. As will be described, the end cap 204 allows components of the tool 200 to provide power to, control and/or communicate with adjacent tools. In this embodiment, the tool 200 comprises two battery clusters 210 and a single electronics cluster 240. As a person skilled in the art will appreciate, the tool 200 may one or more battery clusters 210 and/or electronics clusters 240 depending on the specific application that the tool 200 is being used. For example, an abandoned offshore appraisal well may require multiple battery clusters 210 with multiple electronics clusters 240 while an unused sidetrack of a production well may only require a single battery cluster 210 and a single electronics cluster 240.

As shown in Figure 3, the battery and electronics clusters 210 and 240, respectively, are in longitudinally arranged end-to-end within the tool 200. The clusters 210 and 240 are electrically connected allowing for power and control signal transmission between clusters 210 and 240 as will be described. Longitudinally adjacent clusters 210 and 240 are shown in Figure 3.

Turning now to Figures 4 and 5, cross-sectional views of the battery cluster 210 and electronics clusters 240 taken along section lines A-A and B-B, respectively, are shown.

As shown in Figure 4, the battery cluster 210 is within the enclosure 202. The battery cluster 210 comprises an enclosure 212, slots, batteries 214, conductors 216, connectors 218 and wiring harness 220. The battery cluster 210 is generally cylindrical and has a plain and uniform circumference similar to the tool 200. In this embodiment, the length of the battery cluster 210 is approximately 52.254 inches (132.725 cm). The width or diameter of the batter cluster 210 is less than 5.5 inches (14.0 cm).

As previously stated, the battery cluster 210 is within the enclosure 202. Each individual battery cluster 210 comprises in individual enclosure 212. The enclosure 212 is a pressure enclosure that encloses the other components of an individual battery cluster 210. The enclosure 212 prevents ingress and/or egress of fluids into and out of the individual battery cluster 210.

The slots are spaced through the battery cluster 210. The slots run the length of the battery cluster 210. In this embodiment, the slots are generally cylindrical in shape. The slots define voids where the batteries 214, conductors 216 and wiring harness 220 may be placed within the voids defined by the slots. As will be appreciated, each slot contains one of a battery 214, conductor 216 or wiring harness 220, or may be empty. In this embodiment, slots comprise battery slots configured to contain batteries 214, conductor slots configured to contain conductors 216 and a wiring harness slot configured to contain the wiring harness 220.

In this embodiment, the battery cluster 210 comprises thirteen (13) slots. Six (6) slots are sized for and contain batteries 214. These slots are battery slots sized to contain batteries 214. Six (6) slots are sized for and contain conductors 216. These slots are conductor slots sized to contain conductors 216. One (1) slot is sized for and contains the wiring harness 220. The slots are geometrically arranged in the battery cluster 210. The slot containing the wiring harness 220 is generally centrally located within the battery cluster 210. The slots containing the batteries 214 and conductors 216 are radially oriented around the central wiring harness 220. The batteries 214 are radially adjacent. The conductors 216 are similarly radially adjacent. Specifically, the batteries 214 are radially equidistant from the wiring harness 220. The batteries 214 are equidistant from each other. Each battery 214 is adjacent to two (2) batteries 214 and to two (2) conductors 216.

While the batteries 214 are shown as being identical, a person skilled in the art will appreciate that a variety of batteries 214 may be used. In this embodiment, the batteries 214 are battery cells. In particular, the batteries 214 are D-cells. In this embodiment, one or more of the batteries 214 is a moderate rate battery. In other embodiments, one or more of the batteries 214 is a high rate battery. Furthermore, a variety of battery technologies may be used in the battery cluster 210. For example, one or more batteries 214 may be alkaline type batteries while other batteries are lithium type batteries. Batteries 214 may be installed prior to installation of the battery cluster 210 into the tool 200, or during maintenance or servicing operations of the tool 200.

Each connector 218 is electrically connected to an individual battery 214. Each connector 218 is further electrically connected to the wiring harness 220. The wiring harness 220 is further electrically connected to the conductors 216. In this manner, power is drawn from the batteries 214 through the connectors 218 to the wiring harness 220 and then to the conductors 216. As previously stated the wiring harness 220 is generally centrally located within the battery cluster 210. The wiring harness 220 comprises multiple wires connected to the batteries 214 and conductors 216 within the battery cluster 210. The wiring harness 220 is electrically connected to the connectors 218 and the conductors 220. The wiring harness 220 is configured to connect the batteries 214 (via the connectors 218) in a particular required configuration depending on the power required. For example, the wiring harness 220 may be configured to connect all of the batteries 214 in parallel, series or some combination of the two, e.g. two sets of three series connected batteries 214 in parallel. The wiring harness 220 is configured prior to installation of the battery cluster 210 in the tool 200. As will be appreciated, different battery clusters 210 may comprise wiring harnesses 220 with different configurations.

The conductors 216 are configured to transfer communications signals to or from adjacent clusters (e.g. an electronics cluster 240) or to an adjacent tool, gauge or other element including another tool 200. The conductors 216 are radially equidistant from the wiring harness 220. The conductors 216 are equidistant from each other. Each conductor 216 is adjacent to two (2) batteries 214. In this embodiment, the conductors 216 are cooper. As previously stated, the wiring harness communication signals to or from adjacent clusters or tools, gauges, etc.

The conductors 216 provide direct communication to tools adjacent to the tool 200 via the end cap 204. The conductors 216 transfer communication signals to or from adjacent clusters and/or tools via the end cap 204. The conductors 216 form part of the direct current (DC) resistance (DCR) path for communication signals. As such, in order to optimize communication, resistance in the conductors 216 is minimized.

Furthermore, power are transferred from the batteries 214 through the connectors 218 and wiring harness 220 to adjacent clusters and/or tools. The conductors 216 transfer the power to the end cap 204. As previously stated, the end cap 204 provides for an electrical connection to adjacent tools. A simplified current path is therefore provided to power adjacent tools with power from the batteries 214. Accordingly adjacent tools, such as valves, tubing conveyed perforation (TCP) guns and suspension devices, may by powered via the battery cluster 210 and the tool 200. This may relieve or eliminate the need for these tools to have separate battery systems or downhole power reception/extraction hardware.

The batteries 214 and conductors 216 are arranged such that their weight is generally distributed in the battery cluster 210. The batteries 214 and conductors 216 are sized, numbered and arranged such that the number of batteries 214 and the resistance of the conductors 216 is optimized. In particular, the number of batteries 214 is maximized and the resistance of the conductors 216 is minimized. This may vary depending on the particular power requirements of the battery cluster 210.

As will be appreciated, the battery cluster 210 comprises more batteries 214 per length (i.e. length of the tool 200) then conventional tools where batteries are longitudinally end-to-end. Accordingly, the battery cluster 210 comprises more battery capacity and therefore more power capacity than conventional tools. As such the operational life of the tool 200 is greater than conventional tools as the power capacity is greater.

Turning now to Figure 5, a cross-sectional view of the electronics cluster 240 taken along section lines B-B is shown. The electronics cluster 240 is within the enclosure 202. The electronics cluster 240 comprises an enclosure 242, slots, gauges 244, communication modules 246 and wiring harness 260. The electronics cluster 240 is generally cylindrical and has a plain and uniform circumference similar to the tool 200. In this embodiment, the length of the electronics cluster 240 is approximately 34.764 inches (88.300 cm). The width or diameter of the electronics cluster 240 is less than 5.5 inches (14.0 cm).

As previously stated, the electronics cluster 240 is within the enclosure 202. Each individual electronics cluster 240 comprises an individual enclosure 242. The enclosure 242 is a pressure enclosure that encloses the other components of an individual electronics cluster 240. The enclosure 242 prevents ingress and/or egress of fluids into and out of the individual electronics cluster 240.

The slots are spaced through the electronics cluster 240. The slots runs the length of the electronics cluster 240. In this embodiment, the slots are generally cylindrical in shape. The slots define voids where the gauges 244, communication modules 246 and wiring harness 260 may be placed within the electronics cluster 240. As will be appreciated, each slot contains one of a gauge 244, communication module 246 and wiring harness 260, or may be empty. In this embodiment, slots comprise gauge slots configured to gauges 244, communication module slots configured to contain communication modules 246 and a wiring harness slot configured to contain the wiring harness 260.

In this embodiment, the electronics cluster 240 comprises seven (7) slots. Three (3) slots are sized for and contain gauges 244. These slots are gauge slots sized for gauges 244. Three (3) slots are sized for and contain communication modules 246. These slots are communication module slots sized for communication modules 246. One (1) slot is sized for and contains the wiring harness 260. This slot is a wiring harness lot sized for the wiring harness 260. The slots are geometrically arranged in the electronics cluster 240. The slot containing the wiring harness 260 is generally centrally located within the electronics cluster 240. The slots containing the gauges 244 and communication modules 246 are radially oriented around the central wiring harness 260. The gauges 244 and communication modules 246 are radially adjacent. Furthermore, the gauges 244 and communication modules 246 are radially equidistant from the wiring harness 260. The gauges 244 and communication modules 246 are equidistant from each other.

In this embodiment, at least one gauge 244 is configured to detect a parameter. The gauge 244 comprises a sensor configured to measure, detect or sense one or more of pressure, temperature, strain, force, resistance and conductivity. As will be appreciated, the gauge 244 may comprise one or more sensors. The gauge 244 is further configured to communicate the measured, detected or sensed data to one or more of the communication modules 246 via the wiring harness 260.

In one embodiment, the gauges 244 of the electronics module 240 are interconnected and are configured to combine detected parameters. In one embodiment, at least one of the gauges 244 comprises a processor configured to control interconnection between the gauges 244 and configured to combine detected parameters.

In this embodiment, at least one communication module 246 is configured to communicate with one or more of the gauges 244. Specifically, the communication module 246 is configured to receive data from one or more of the gauges 244. The communication module 246 is further configured to communicate the data from the gauge 244 to one or more locations remote of the tool 200. In this embodiment, one or more communication modules 246 are configured to, additionally or alternatively, communicate data to at least one gauge 244, for example, control signals to the gauge 244.

In this embodiment, the communication module 246 comprises a receiver, transmitter or transceiver. In this embodiment, the communication module 246 employs wired and/or wireless communication methods. Wired communication methods are through a guided transmission medium, such as a wire, other metallic structure or a material having high electromagnetic (EM) conductivity relative to a surrounding medium. Wired communication methods may utilize e-lines, slicklines, fibre optic cabling, etc. Wireless communication methods are not through a guided transmission medium. Wireless communication methods are through air, water, ground (or formation) or another medium that has substantially isotropic EM conductivity. In some or more examples, wireless communication methods utilize electromagnetic technology, acoustic technology and/or pressure wave technology.

In this embodiment, the communication module 246 is configured to couple, via the enclosure 242 of the electronics cluster 240, to the enclosure 202 of the tool 200 to transmit a signal wirelessly. In this embodiment, the communication module 246 is configured to couple to tubing mounted centralizers and/or isolation joints within the well structure 102 of the well 100.

The gauges 244 and communications modules 246 are installed prior to installation of the electronics module 240 into the tool 200, or during maintenance or servicing operations on a tool 200.

Each gauge 244 and communication module 246 is electrically connected to the wiring harness 260. The wiring harness 260 comprises multiple wires configured to the gauges 244 and communication modules 246 within the electronics cluster 240. The wiring harness 260 is configured to permit signal communication between individual gauges 244, individual communication modules 246, and gauges 244 and communication modules 246. Information or signals communicated to a communication module 246 is communicated to other communication modules 246 and/or gauges 244 via the wiring harness 260. Similarly, data from the gauges 244 is communicated to other gauges 244 and/or communication modules 246 via the wiring harness 260.

The wiring harness 260 further comprises wires connected to the end cap 204 of the tool 200. As such, parameter detected by the gauges 244 may be transferred via the wires of the wiring harness 260 and the end cap 204 to one or more adjacent tools (e.g. valves, TCP guns, suspension device, etc.). The wiring harness 260 and end cap 204 offer a direct electrical connection from the gauges 244 to adjacent tools. These adjacent tools are therefore not required to include similar gauges 244. This reduces the size of adjacent tools as well hardware and saves on costs.

In addition, data communicated to the communication modules 246 (from the gauges 244 or from a remote location) may be transferred via thee wires of the wiring harness 260 and the end cap 204 to one or more adjacent tools. The wiring harness 260 and end cap 204 offer a direct electrical connection from the communication modules 246 to adjacent tools. Accordingly, communication hardware is not required on the adjacent tools which reduces the size of the adjacent tool and saves on costs. The communication modules 246 may therefore control these adjacent tools directly. This provides for a single wireless or wired communication path, i.e. from the communication modules 246 to the remote location providing control signals, rather than multiple wired or wireless communication paths to each individual tool. Accordingly, system complexity and costs are reduced.

The gauges 244 and communication modules 246 are arranged such that their weight is generally distributed in the electronics cluster 240. As will be appreciated, the specific gauges 244 and communication modules 246 as well as the number of gauges and communication modules 246 may vary depending on the use case of the tool 200.

As will be appreciated, the electronics cluster 240 comprises more components (gauges 244 and communication modules 246) per length (i.e. length of the tool 200) then conventional tools where components (gauges and communication modules) are arranged longitudinally end-to-end. Accordingly, the electronics cluster 240 comprises more sensing and communication capabilities than conventional tools. As such, the tool 200 may be used in wide variety of applications. Furthermore, the tool 200 is more adaptable such that a wide variety of gauges 244 and communication modules 246 may be present in a single electronics module 240. Accordingly, the tool 200 may operate in a wide variety of applications.

In operation, a communication module 246 receives a control signal from a remote location, for example a location uphole of the tool 200 such as a control centre at the surface, via wireless communication. The communication module 246 then communicates the control signal to the gauge 244 via the wiring harness 260. The control signal instructs the gauge 244 to detect a particular parameter such as the temperature surrounding the tool 200. The gauge 244 then communicates the detected parameter to the communication module 246 via the wiring harness 260. The communication module 246 communicates the detected parameter via wireless communication to the remote location. The detected parameter is may additional or alternatively be transferred via the conductors 216 of the battery cluster 210 to adjacent clusters and/or tools.

As will be appreciated, the described operations may be performed by a single communication module 246 and a single gauge 244, multiple communication modules 246 and multiple gauges 244, or combinations thereof.

In this embodiment, the tool 200 is deployed into the well tubing of the well structure 102 with an e-line. The e-line is configured for single run verification. Thus all of the components, e.g. the clusters 210 and 240, may be verified with a single run via the e- line. In contrast, multiple conventional tools are normally necessary to achieve the functionality of the clusters 210 and 240 described, and accordingly, multiple verification runs are required. As will be appreciated, the tool 200 may therefore be quickly installed and/or deployed in the well 100. Installation/deployment time and costs are therefore reduced.

The applicant discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.