Note: Descriptions are shown in the official language in which they were submitted.
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BLADE-MOUNTED SENSOR
APPARATUS, SYSTEMS, AND METHODS
BACKGROUND
[0001] Understanding the structure and properties of geological formations
may reduce the cost of drilling wells for oil and gas exploration.
Measurements
are typically performed in a borehole (i.e., downhole measurements) in order
to
attain this understanding. For example, the measurements may identify the
composition and distribution of material that surrounds the measurement device
downhole.
[0002] Measurement While Drilling (MWD) and Logging While Drilling
(LWD) tools are often used to make such measurements, to help determine when
hydrocarbon deposits are embedded in the surrounding formation. Temperature,
pressure, and vibration may also be measured downhole, among other
conditions. These measurements constitute data gathered by the MWD/LWD
tool, and may be sent up to the surface in real time (e.g., in MWD), or
retrieved
at a later time (e.g., in LWD), after drilling operations are completed. Such
measurements can be made using sensors or transducers, which may be fixed or
movable, perhaps mounted along the MWD/LWD tool body, or on a probe that
extends outwardly from the tool body. Sometimes these probes are expensive to
manufacture, or difficult to replace.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 illustrates a blade-mounted sensor apparatus employed in two
locations on a drill string, according to various embodiments.
[0004] FIG. 2 provides perspective and top plan views of blades forming a part
of a blade-mounted sensor apparatus, according to various embodiments.
[0005] FIG. 3 provides perspective and close-up views of a single blade,
forming part of an apparatus, according to various embodiments.
[0006] FIG. 4 illustrates top and perspective views of an apparatus having
four
blades in retracted and extended positions, respectively, according to various
embodiments.
[0007] FIG. 5 illustrates top and perspective views of an apparatus having two
blades in retracted and extended positions, respectively, according to various
embodiments.
[0008] FIG. 6 illustrates top and perspective views of an apparatus having
three blades in retracted and extended positions, respectively, according to
various embodiments.
[0009] FIG. 7A illustrates a side perspective view of a gear extension
mechanism, and a top plan view, with a perspective view inset of a hydraulic
actuator extension mechanism, according to various embodiments.
[0009A] FIG. 7B illustrates a breakout view of different types of actuators.
[0010] FIG. 8 illustrates a perspective view of an array of blade sets,
according
to various embodiments.
[0011] FIG. 9 illustrates side views of an apparatus, with blades in a
retracted
position, and an extended position to stabilize a drill string, respectively,
according to various embodiments.
[0012] FIG. 10 is a block diagram of apparatus and systems according to
various embodiments of the invention.
[0013] FIG. 11 is a flow chart illustrating several methods according to
various embodiments of the invention.
[0014] FIG. 12 illustrates a wireline system, according to various
embodiments of the invention.
[0015] FIG. 13 illustrates a drilling rig system, according to various
embodiments of the invention.
DETAILED DESCRIPTION
10015A] According to an aspect of the disclosure, there is provided an
apparatus,
comprising: a tubular member; at least two interchangeable blades attached to
the tubular member, the blades extendible radially outward to an extended
position and retractable radially inward to a retracted position, wherein an
outer
surface of the blades is disposed at or below an outer surface of the tubular
member when the blades are in the retracted position; and a plurality of
sensors
attached to the blades, the sensors to engage a circumferential portion of a
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borehole wall along the outer surface of the blades in an azimuthal direction
when the blades are disposed downhole in the extended position, and to refrain
from engaging thc borehole wall when the blades are disposed downhole in the
retracted position.
[0015B] In some embodiments, the tubular member comprises one of a drilling
collar or a crossover sub.
10015C1 In some embodiments, the at least two interchangeable blades comprise
identical blades.
[0015D] In some embodiments, the at least two interchangeable blades comprise
three or four interchangeable blades, each of the blades occupying a
substantially
similar portion of a circumference of the tubular member when the blades are
in
the retracted position.
[0015E] In some embodiments, each of the blades overlap at least one other one
of the blades along the circumference of the tubular member when the blades
are
in the retracted position.
[0015F] In some embodiments, the apparatus further comprises: gears,
electromagnetic, piezoelectric, shape memory alloy, or hydraulic actuators to
couple the tubular member to the blades.
10015G1 In some embodiments, the plurality of sensors comprise at least two
different sensor types arranged on one of the blades.
[0015H] In some embodiments, each of the blades includes end pieces that
engage end pieces of other blades in a mirrored fashion when the blades are in
the retracted position.
10015111 In some embodiments, the outer surface of the blades substantially
conforms to the outer surface of the tubular member, to form a substantially
continuous outer surface, when the blades are in the retracted position.
10015J] In some embodiments, each of the blades is attached to the tubular
member at a single point of rotation.
[0015K] In some embodiments, the single point of rotation comprises an
aperture in the blade extending in a longitudinal direction of the tubular
member
and located on an interlocking portion of the blade.
[0015L] In some embodiments, the sensors comprise at least one transducer.
[0015M] In some embodiments, each of the blades is formed in a crescent shape.
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[0015N1 In some embodiments, the apparatus further comprises: multiple sets of
the at least two interchangeable blades, each of the sets attached to the
tubular
member at a different longitudinal location.
[00150] In some embodiments, at least some of the plurality of sensors form a
portion of the outer surface of the blades.
[0015P1 According to another aspect of the disclosure, there is provided a
system, comprising: a controller; and an apparatus operatively coupled to the
controller, the apparatus comprising a tubular member attached to at least two
interchangeable blades, the blades extendible radially outward responsive to
receiving an extend command issued by the controller, to an extended position,
and retractable radially inward responsive to receiving a retract command
issued
by the controller, to a retracted position, wherein an outer surface of the
blades is
disposed at or below an outer surface of the tubular member when the blades
are
in the retracted position; and a plurality of sensors attached to the blades,
the
sensors to engage a circumferential portion of a borehole wall along the outer
surface of the blades in an azimuthal direction when the blades are disposed
downhole in the extended position, and to refrain from engaging the borehole
wall when the blades are disposed downhole in the retracted position.
[0015Q] In some embodiments, the tubular member comprises a portion of a
drill string, and the apparatus operates as a passive stabilizer to centralize
the
drill string when the blades are in the extended position.
[0015R] In some embodiments, the outer surface of the blades operate to
complete the outer surface of the tubular member when the blades are in the
retracted position.
[0015S] According to another aspect of the disclosure, there is provided a
method, comprising: lowering a tubular member into a borehole while at least
two interchangeable blades attached to the tubular member are in a retracted
position, the blades retractable radially inward from an extended position to
the
retracted position, wherein an outer surface of each of the blades is disposed
at
or below an outer surface of the tubular member when the blades are in the
retracted position; and extending the blades radially outward into the
extended
position to engage, by the outer surface of each one of the blades and a
plurality
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of sensors attached to the blades in an azimuthal direction, a circumferential
portion of a wall of the borehole.
[0015T] In some embodiments, extending the blades further comprises: rotating
a geared mechanism or activating an electromagnetic, piezoelectric, shape
memory alloy, or hydraulic actuator attached to the blades.
[0015U] In some embodiments, the method further comprises: measuring a
resistance force encountered by one or more of the blades; and ceasing to
extend
the blades when a preselected amount of the resistance force is measured.
[0015V] In some embodiments, the method further comprises: acquiring sensor
data from the plurality of sensors, wherein at least two different sensor
types are
located on at least one of the blades.
[0015W] In some embodiments, the method further comprises: retracting the
blades radially inward into the retracted position; drilling into a geological
formation surrounding the borehole, to extend a length of the borehole, using
a
drill string that includes the tubular member; and extending the blades
radially
outward into the extended position to stabilize the drill string within the
borehole.
[0016] Apparatus, systems, and methods are described herein that provide a
new mechanism to mount sensors when making downhole measurements. For
example, in some embodiments, the sensors can be attached to a drill collar
and/or a crossover substitute (also known as a crossover sub to those of
ordinary
skill in the art). The sensors are mounted on blades that, upon activation,
operate
to extend radially outward toward the borehole wall, to come in contact with
the
surrounding formation. This mode of operation enhances the coupling effect
between the sensors and the formation, often enhancing the accuracy of the
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associated measurement. In some embodiments, multiple sensors are attached to
a single blade to offer different sensing services at particular location. The
details of various embodiments will now be described.
[0017] FIG. 1 illustrates a blade-mounted sensor apparatus 100 employed in
two locations on a drill string, according to various embodiments. In the
figure, a
drill string 110 is shown to include an MWD/LWD collar 120 and a crossover
sub 130. The apparatus 100, including blades 150 can be formed as part of the
collar 120, as well as the crossover sub 130. As will be shown in later
figures,
the apparatus 100 may comprise two or more blades 150. In this figure, the
apparatus 100 has four blades 150.
[0018] FIG. 2 provides perspective 120 and top plan views 220, 230 of blades
forming a part of a blade-mounted sensor apparatus, according to various
embodiments. These crescent-shaped blades 150 are shown in this figure to have
a leading edge 240, and trailing edge 242. The leading edge 240 slopes
downward (underneath the substantially flat table 260) along a downward
sloping surface 268, toward a substantially flat base 250. The trailing edge
242
rises above the substantially flat base 250, upward along an upward sloping
surface 264, toward a peak 254, which terminates at an edge of the
substantially
flat table 260. In many embodiments, the substantially flat table 260 and/or
the
downward sloping surface 268 include an aperture 270 that forms a point of
rotation when the blade 150 is attached to a tubular member (not shown). The
aperture 270 may be attached to the tubular member using a pin 274, for
example.
[0019] In the figure, the top plan view 210 shows a set of four blades 150 in
a
retracted position, wherein the outer surfaces 272 of the blades 150 combine
to
form a circle that is, in many embodiments, the same diameter as the tubular
member to which the blades 150 are attached. This feature enables the blades
150, when in the retracted position, to conform to the outer surface of the
tubular
member to which they are attached, by matching the outer circumference of a
drilling collar or crossover sub, for example (e.g., see FIG. 1).
[0020] FIG. 3 provides perspective and close-up views of a single blade 150,
forming part of an apparatus 100, according to various embodiments. Here it
can
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be seen that the apparatus 100, comprising a tubular member 300 and multiple
blades 150, may be fabricated so that multiple sensors 310 are mounted to each
blade. For example, in the close up view of the blade 150, three different
sensor
types are shown: an electrode E, a transducer '1', and a coil C. Many other
sensor
types may be supported, such as temperature, vibration, etc.
[0021] As shown in the figure, the blades 150 are movable from the retracted
position (not shown) to an extended position (shown). The blades 150 may also
be constructed to as to be interchangeable, one for another. This allows a
variety
of sensing services to be provided with a single blade design. In some
embodiments, as shown, the blades are also fabricated so as to be identical,
malcing repair and substitution of the blades 150 relatively easy. Individual
blades 150 may include wiring connections 320 on the inner surfaces 330 of the
blades 150, providing electrical connectivity to the attached sensors 310. In
this
figure, it can also be seen how the outer surface 272 of the blades 150 does
not
conform to the outer surface 340 of the tubular member 300 when the blades are
in the extended position.
[0022] FIG. 4 illustrates top 410,420 and perspective views 430, 440 of an
apparatus 100 having four blades 150 in retracted and extended positions,
respectively, according to various embodiments. The operational modes of the
blades 150 thus include the retracted position (shown in view 430) and, after
the
blades have moved radially outward to contact the borehole wall 450, the
extended position (shown in view 440). In view 430, it can also be seen how
the
outer surface 272 of the blades 150 conforms to and completes the outer
surface
340 of the tubular member 300 when the blades are in the retracted position.
[0023] In many embodiments, the tubular member 300 that forms part of an
MWD/LWD tool will rotate during drilling operations, and then rotation will
stop at some point. This may occur for a number of reasons, including to
provide
an opportunity to measure conditions in the borehole, such as formation
pressure, seismic activity, etc. It is at this point that an extension
mechanism will
be activated, to move the blades 150 from the retraction position (see view
430)
to the extended position (see view 440), so that the blades 150 are contacting
the
4
borehole wall 450. Other numbers of blades 150 may be used in various
embodiments.
[0024] For example, FIG. 5 illustrates top 510, 520 and perspective views 530,
540 of an apparatus 100 having two blades 150 in retracted and extended
positions, respectively, according to various embodiments. The operational
modes of the blades 150 again include the retracted position (shown in view
530)
and, after the blades 150 have moved radially outward to contact the borehole
wall 450, the extended position (shown in view 540).
[0025] In another example, FIG. 6 illustrates top 610, 620 and perspective
views 630, 640 of an apparatus 100 having three blades 150 in retracted and
extended positions, respectively, according to various embodiments. The
operational modes of the blades 150 again include the retracted position
(shown
in view 630) and, after the blades 150 have moved radially outward to contact
the borehole wall 450, the extended position (shown in view 640).
[0026] FIG. 7A illustrates a side perspective view 710 of a gear extension
mechanism 715, and a top plan view, with a perspective view inset 730 of a
hydraulic actuator extension mechanism 735, according to various embodiments.
Thus, two possible extension mechanisms 715, 735, among many, can be used to
extend and retract the blades 150 by urging the blades 150 radially outward,
and
rotating the blades 150 around the pins 274. In some embodiments, extension
activity may cease when the blades 150 undergoing extension experience a
sufficient counter-resistance force F, perhaps by coming into contact with a
borehole wall, or a geological formation. Once contact is made, the sensors
310
can operate to provide measurement signals to other parts of a downhole
measurement and data acquisition system.
[0027] FIG. 8 illustrates a perspective view of an array 800 of blade sets
810,
according to various embodiments. This arrangement provides the flexibility of
using different sensor groups 820', 820" arranged in an array configuration
along the longitudinal direction Z of the tubular member 300. For example, the
sensors in group 820' may be ultrasonic transducers, and the sensors in group
820" may be electrodes
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[0028] FIG. 9 illustrates side views 910, 920 of an apparatus 100, with blades
in a retracted position, and an extended position to stabilize a drill string,
respectively, according to various embodiments. In the first view 910, the
blades
of the apparatus 100 are shown in the retracted position. This position may be
appropriate when drilling activity is ongoing in the borehole 930.
[0029] In the second view 920, the apparatus 100 is acting as a passive
centralizer for the drill string 940. Thus, when the centerline 960 of the
drill
string 940 runs out from the centerline 970 of the borehole 930, the blades
150
can be activated to extend toward the toward the wall 950 of the borehole 930,
in
order to passively centralize the drill string 930 near the longitudinal
location on
the drill string 930 where the apparatus 100 is attached. Still further
embodiments may be realized.
Apparatus and Systems
[0030] For example, FIG. 10 is a block diagram of apparatus 100 and systems
1000 according to various embodiments of the invention. Here, it can be seen
that the system 1000 may include a controller 1025 specifically configured to
interface with a controlled device 1070, such as an extension/retraction
mechanism for the apparatus 100, a geosteering unit, and/or a user display or
touch screen interface (in addition to displays 1055), The system 1000 may
further include sensors 310, such as electromagnetic transmitters and
receivers,
transducers, etc. (see FIG. 3), attached to the blades of the apparatus 100.
When
configured in this manner, the system 1000 can receive measurements and other
data (e.g., location and conductivity or resistivity information, among other
data)
to be processed according to various methods described herein.
[0031] A processing unit 1002 can be coupled to the apparatus 100 to obtain
measurements from the sensors 310, and other components that may be attached
to a housing 1004. Thus, in some embodiments, a system 1000 comprises a
housing 1004 that can be attached to or used to house the apparatus 100, and
perhaps the controlled device 1070, among other elements. The housing 1004
might take the form of a wireline tool body, or a downhole tool as described
in
more detail below with reference to FIGs. 12 and 13. The processing unit 1002
may be part of a surface workstation, or attached to the housing 1004.
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[0032] The system 1000 can include other electronic apparatus 1065, and a
communications unit 1040. Electronic apparatus 1065 (e.g., electromagnetic
sensors, current sensors, and other devices) can also be used in conjunction
with
the controller 1025 to perform tasks associated with taking measurements
downhole. The communications unit 1040 can be used to handle downhole
communications in a drilling operation. Such downhole communications can
include telemetry.
[0033] The system 1000 can also include a bus 1027 to provide common
electrical signal paths between the components of the system 1000. The bus
1027 can include an address bus, a data bus, and a control bus, each
independently configured. The bus 1027 can also use common conductive lines
for providing one or more of address, data, or control, the use of which can
be
regulated by the controller 1025 and/or the processing unit 1002.
[0034] The bus 1027 can include instrumentality for a communication
network. The bus 1027 can be configured such that the components of the
system 1000 are distributed. Such distribution can be arranged between
downhole components such as the components attached to the housing 1004, and
components that are located on the surface of a well. Alternatively, several
of
these components can be co-located, such as on one or more collars of a drill
string or on a wireline structure.
[0035] In various embodiments, the system 1000 includes peripheral devices
that can include displays 1055, additional storage memory, or other control
devices that may operate in conjunction with the controller 1025 or the
processing unit 1002. The displays 1055 can display diagnostic and
measurement information for the system 1000, based on the signals generated
according to embodiments described above.
[0036] In an embodiment, the controller 1025 can be fabricated to include one
or more processors. The display 1055 can be fabricated or programmed to
operate with instructions stored in the processing unit 1002 (for example in
the
memory 1006) to implement a user interface to manage the operation of the
system 1000, including any one or more components distributed within the
system 1000. This type of user interface can be operated in conjunction with
the
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communications unit 1040 and the bus 1027. Various components of the system
1000 can be integrated with a bottom hole assembly, if desired, which may in
turn be used to house the apparatus 100, such that operation of the apparatus
100, and processing of the measurement data, identical to or similar to the
methods discussed previously, and those that follow, can be conducted
according
to various embodiments that are described herein.
[0037] In some embodiments, a non-transitory machine-readable storage
device can comprise instructions stored thereon, which, when performed by a
machine, cause the machine to become a customized, particular machine that
performs operations comprising one or more features similar to or identical to
those described with respect to the methods and techniques described herein. A
machine-readable storage device, as described herein, is a physical device
that
stores information (e.g,, instructions, data), which when stored, alters the
physical structure of the device. Examples of machine-readable storage devices
can include, but are not limited to, memory 1006 in the form of read only
memory (ROM), random access memory (RAM), a magnetic disk storage
device, an optical storage device, a flash memory, and other electronic,
magnetic, or optical memory devices, including combinations thereof.
[0038] The physical structure of stored instructions may be operated on by one
or more processors such as, for example, the processing unit 1002. Operating
on
these physical structures can cause the machine to become a specialized
machine
that performs operations according to methods described herein. The
instructions can include instructions to cause the processing unit 1002 to
store
associated data or other data in the memory 1006. The memory 1006 can store
the results of measurements of formation parameters, to include gain
parameters,
calibration constants, identification data, sensor location information,
sensor
extension/retraction force information, etc. The memory 1006 can store a log
of
the measurement and location information provided by the system 1000. The
memory 1006 therefore may include a database, for example a relational
database. The processors 1030 can be used to process the data 1070 to form
images of cement surrounding a well, or the formation itself.
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[0039] Thus, referring to FIGs. 1-10, it can be seen that many embodiments
may be realized. For example, an apparatus 100 may comprise a tubular member
MX) attached to at least three mechanically interchangeable blades 150, with
multiple sensors 310 mounted on the blades.
[0040] In some embodiments, an apparatus 100 comprises a tubular member
300 and at least two interchangeable blades 150 attached to the tubular
member300. The blades 150 being extendible radially outward to an extended
position, and retractable radially inward to a retracted position. The outer
surface
272 of the blades 150 is disposed at or below an outer surface of the tubular
member 300 when the blades 150 are in the retracted position. In some
embodiments, a plurality of sensors 410 fool' a portion of the outer surface
272
of the blades 150, the sensors 310 engaging a circumferential portion of a
borehole wall 450 along the outer surface 272 of the blades 150 in an
azimuthal
direction when the blades 150 are disposed downhole in the extended position.
The sensors 310 refrain from engaging the borehole wall 450 when the blades
150 are disposed downhole in the retracted position.
[0041] The tubular member may take the form of a drilling collar, or a
crossover substitute device, or crossover sub. Thus, in some embodiments, the
tubular member 300 comprises one of a drilling collar 120 or a crossover sub
130.
[0042] The blades are often interchangeable, and may be identical. Thus, the
interchangeable blades 150 comprise identical blades in some embodiments.
[0043] There may be three or four blades (or more) attached to the tubular
member, occupying substantially equal portions of the circumferential distance
around the outer surface of the tubular member. Thus, in some embodiments, the
at least two interchangeable blades 150 comprise three or four interchangeable
blades 150, each of the blades 150 occupying a substantially similar portion
of a
circumference of the tubular member 300 when the blades 150 are in the
retracted position (see views 420, 520, 620 in FIGs. 4, 5, 6, respectively).
[0044] Each of the blades may overlap another blade when in the retracted
position. In some embodiments, each blade overlaps two other blades. Thus, in
some embodiments, each of the blades 150 overlap at least one other one of the
9
blades 150 along the circumference of the tubular member when the blades 150
are in the retracted position (see e.g., views 420 and 440 in FIG. 4).
[0045] Gears and/or a variety of actuators 735 may be used to extend and
retract the blades. Thus, in some embodiments, gears, electromagnetic,
piezoelectric, shape memory alloy, or hydraulic actuators are attached so as
to
couple the tubular member 300 to the blades 150 (see e.g., views 710 and 720,
and breakout view of the different types of actuators 735, in FIG. 7B).
[0046] Different sensor types may be attached to different blades, or the same
blades. Thus, in some embodiments, the plurality of sensors 310 comprise at
least two different sensor types arranged on one of the blades (see e.g.,
inset
view of FIG. 3). In some embodiments, the blade sensors comprise one or more
transducers (that provide a two-way conversion to and from electrical
signals).
100471 When in the retracted position, the ends of the blades may engage the
ends of other blades, in a mirrored fashion. Thus, in some embodiments, each
of
the blades 150 includes end pieces that engage end pieces of other blades in a
mirrored fashion (e.g., one end piece comprising the leading edge 240 and
downward sloping surface 268 of one blade 150, and another end piece
comprising the trailing edge 242 and upward sloping surface 264 of another
blade 150) when the blades are in the retracted position.
[0048] When in the retracted position, the outer surfaces of the blades may
meet the outer surface of the tubular member, to form a unified outer surface.
Thus, in some embodiments, the outer surface 272 of the blades 150
substantially conforms to the outer surface 340 of the tubular member 300, to
form a substantially continuous outer surface, when the blades 150 are in the
retracted position (e.g., see view 430 in FIG. 4).
[0049] The blades may be attached to the tubular member using a rotating
joint. Thus, in some embodiments, each of the blades 150 is attached to the
tubular member 300 at a single point of rotation (e.g., using a pin 274).
[0050] The tubular member may be attached to a number of pins that retain the
blades via an aperture formed in each blade. Thus, in some embodiments, the
single point of rotation comprises an aperture 270 in the blade 150 extending
in a
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longitudinal direction of the tubular member 300 and located on an
interlocking
portion of the blade (e.g., the edge 240, and the downward sloping surface
268).
[0051] The blades may take a variety of forms, including that of a
crescent. Thus, in some embodiments, each of the blades 150 is formed in a
crescent shape (e.g., see blades 150 in view 230 of FIG. 2). Some sensors 310
operate best when a certain amount of standoff distance is maintained between
the sensor face and the borehole wall. Other sensors operate best when in full
contact between the sensor face and the borehole wall is maintained. The
crescent shape can be useful in many embodiments precisely for this reason:
there is the flexibility to mount sensors 310 on different locations of the
outer
surface 272 of the blade 150, depending on the usage of each individual sensor
310. Thus, when a particular crescent-shaped blade 150 is extended to engage
the borehole wall, some sensors 310 mounted on the blade will be in direct
contact with the wall, and other sensors will be provided with the proper
standoff
between the sensor face and the wall.
[0052] More than one set of blades may be installed along the length of the
tubular member, to form an array of blade sets. Thus in some embodiments, and
apparatus 100 comprises multiple sets 810 of the at least two interchangeable
blades 150, each of the sets 810 attached to the tubular member 300 at a
different
longitudinal location (along the longitudinal axis Z).
[0053] A system 1000 may include a controller 1025 coupled to the multi-
blade apparatus 100, similar to or identical to the apparatus 100 described
previously. That is, in some embodiments the apparatus 100 is operatively
coupled to the controller 1025, with the apparatus 100 comprising a tubular
member 300 attached to at least two interchangeable blades 150. The blades 150
are extendible radially outward responsive to receiving an extend command
issued by the controller 1025, to an extended position, and retractable
radially
inward responsive to receiving a retract command issued by the controller
1025,
to a retracted position. An outer surface 272 of the blades 150 is disposed at
or
below an outer surface 340 of the tubular member 300 when the blades 150 are
in the retracted position.
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[0054] In some embodiments, the system 1000 further includes a plurality of
sensors 310 attached to the blades 150. The sensors 310 may form a portion of
the outer surface 272 of the blades 150. The sensors 310 are attached to the
blades 150 so as to engage a circumferential portion of a borehole wall along
the
outer surface 272 of the blades 150 in an azimuthal direction when the blades
150 are disposed downhole in the extended position. The sensors 310 are also
attached to the blades 150 so as to refrain from engaging the borehole wall
when
the blades 150 are disposed downhole in the retracted position. In some
embodiments, a processing unit 1002 is coupled to the apparatus in lieu of the
controller 1025, the processing unit 1002 programmed to issue the commands to
extend and retract. In some embodiments, the system 1000 comprises both a
processing unit 1002 and a controller 1025, with the controller 1025 receiving
the extend and retract conamands from the processing unit 1002, and the
controller 1025 operating as an interface to a controlled device 1070
comprises
extension/retraction mechanisms (e.g., gears, hydraulic actuators, etc.).
[0055] The multi-blade apparatus can operate as a passive stabilizer. Thus, in
some embodiments, the tubular member 300 comprises a portion of a drill string
940, and the apparatus 100 operates as a passive stabilizer to centralize the
drill
string 940 when the blades 150 are in the extended position (e.g., see view
920
in FIG. 9).
[0056] When retracted, the outer surface of the blades may operate to form
part of the outer surface of the tubular member. Thus, in some embodiments,
the
outer surface 272 of the blades 150 operate to complete the outer surface of
the
tubular member 300 when the blades are in the retracted position (e.g., see
views
430, 530, 630 in FIGs. 4, 5, 6, respectively).
[0057] The apparatus 100, system 1000, and each of their elements may all be
characterized as "modules" herein. Such modules may include hardware
circuitry, and/or a processor and/or memory circuits, software program modules
and objects, and/or firmware, and combinations thereof, as desired by the
architect of the apparatus 100 and systems 1000, and as appropriate for
particular
implementations of various embodiments. For example, in some embodiments,
such modules may be included in an apparatus 100 and/or system 1000 operation
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simulation package, such as a software electrical signal simulation package, a
power usage and distribution simulation package, a power/heat dissipation
simulation package, a foimation imaging package, an energy detection and
measurement package, and/or a combination of software and hardware used to
simulate the operation of various potential embodiments.
[0058] It should also be understood that the apparatus 100 and systems 1000
of various embodiments can be used in applications other than for logging
operations, and thus, various embodiments are not to be so limited. The
illustrations of apparatus 100 and systems 1000 are intended to provide a
general
understanding of the structure of various embodiments, and they are not
intended
to serve as a complete description of all the elements and features of
apparatus
and systems that might make use of the structures described herein.
[0059] Applications that may include the novel apparatus and systems of
various embodiments include electronic circuitry used in high-speed computers,
communication and signal processing circuitry, modems, processor modules,
embedded processors, data switches, and application-specific modules. Such
apparatus and systems may further be included as sub-components within a
variety of electronic systems, such as televisions, cellular telephones,
personal
computers, workstations, radios, vehicles, geothermal tools, and smart
transducer
interface node telemetry systems, among others. Some embodiments include a
number of methods.
Methods
[0060] FIG. 11 is a flow chart illustrating several methods 1111 according to
various embodiments of the invention. The methods 1111 may comprise
processor-implemented methods, to execute on one or more processors that
perform the methods. For example, one embodiment of the methods 1111 may
begin at block 1121 with lowering the apparatus with retracted blades into a
borehole, and extending the blades to engage the borehole wall at block 1125,
[0061] In some embodiments, a method 1111 begins at block 1121 with
lowering a tubular member into a borehole while at least two interchangeable
blades attached to the tubular member are in a retracted position, with the
blades
being retractable radially inward from an extended position to the retracted
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position. When in the retracted position, the outer surface of each of the
blades is
disposed at or below the outer surface of the tubular member.
[0062] The method 1111 includes, in some embodiments, extending the blades
radially outward into the extended position at block 1125 to engage, by the
outer
surface of each one of the blades and a plurality of sensors forming a portion
of
the outer surface of each one of the blades in an azimuthal direction, a
circumferential portion of a wall of the borehole.
[0063] To extend the blades, a geared mechanism or an actuator can be used.
Thus, in some embodiments, the activity at block 1125 further comprises
rotating a geared mechanism or activating an electromagnetic, piezoelectric,
shape memory alloy, or hydraulic actuator attached to the blades.
[0064] The blades can be extended until a certain preselected amount of
resistive counter-force is measured with respect to one or more of the blades,
or
until a substantially equal counter-force is measured on each blade. Thus, in
some embodiments, the activity at block 1125 further comprises measuring a
resistance force encountered by one or more of the blades, and ceasing to
extend
the blades when a preselected amount of the resistance force is measured.
[0065] Sensor data can be acquired from different sensor types. Thus, in some
embodiments, the method 1111 comprises, at block 1129, acquiring sensor data
from the plurality of sensors, wherein at least two different sensor types are
located on at least one of the blades.
[0066] The blades can be retracted to enable drilling operations, and then the
blades can be extended to stabilize the tubular member, as well as the
attached
drill string. Thus, in some embodiments, the method 1111 includes retracting
the
blades radially inward into the retracted position at block 1131, and drilling
into
a geological formation surrounding the borehole at block 1133, to extend the
length of the borehole, using a drill string that includes the tubular member.
[0067] In some embodiments, the method 1111 may return to block 1125, to
include extending the blades radially outward into the extended position to
stabilize the drill string within the borehole. In some embodiments, the
method
1111 may continue from block 1133 to return to 1121, to repeat the activities
designated therein, as well as in the other blocks of the method 1111.
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[0068] It should be noted that the methods described herein do not have to be
executed in the order described, or in any particular order, Moreover, various
activities described with respect to the methods identified herein can be
executed
in iterative, serial, or parallel fashion. The various elements of each method
(e.g., the methods shown in FIG. 11) can be substituted, one for another,
within
and between methods. Information, including parameters, commands, operands,
and other data, can be sent and received in the form of one or more carrier
waves,
[0069] Upon reading and comprehending the content of this disclosure, one of
ordinary skill in the art will understand the manner in which a software
program
can be launched from a computer-readable medium in a computer-based system
to execute the functions defined in the software program. One of ordinary
skill
in the art will further understand the various programming languages that may
be
employed to create one or more software programs designed to implement and
perform the methods disclosed herein.
[0070] For example, the programs may be structured in an object-orientated
format using an object-oriented language such as Java or C#. In another
example, the programs can be structured in a procedure-orientated format using
a procedural language, such as assembly or C. The software components may
communicate using any of a number of mechanisms well known to those of
ordinary skill in the art, such as application program interfaces or
interprocess
communication techniques, including remote procedure calls. The teachings of
various embodiments are not limited to any particular programming language or
environment. Thus, other embodiments may be realized.
Wireline and Drilling Systems
[0071] For example, FIG. 12 illustrates a wireline system 1264, according to
various embodiments of the invention. FIG. 13 illustrates a drilling rig
system
1364, according to various embodiments of the invention. Therefore, the
systems
1264, 1364 may comprise portions of a wireline logging tool body 1270 as part
of a wireline logging operation, or of a downhole tool 1324 as part of a
downhole drilling operation. The systems 1264 and 1364 may include any one
or more elements of the apparatus 100 and systems 1000 shown in FIGs. 1-10.
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[0072] Thus, FIG. 12 shows a well during wireline logging operations.
In this case, a drilling platform 1286 is equipped with a derrick 1288 that
supports a hoist 1290.
[0073] Drilling oil and gas wells is commonly carried out using a string of
drill
pipes connected together so as to form a drilling string that is lowered
through a
rotary table 1210 into a wellbore or borehole 1212. Here it is assumed that
the
drilling string has been temporarily removed from the borehole 1212 to allow a
wireline logging tool body 1270, such as a probe or sonde, to be lowered by
wireline or logging cable 1274 into the borehole 1212. Typically, the wireline
logging tool body 1270 is lowered to the bottom of the region of interest and
subsequently pulled upward at a substantially constant speed.
[0074] During the upward trip, at a series of depths, various instruments
included in the tool body 1270 may be used to perform measurements (e.g.,
made by sensors 310 attached to the apparatus 100 shown in FIG. 3) on the
subsurface geological formations 1214 adjacent the borehole 1212 (and the tool
body 1270). The borehole 1212 may represent one or more offset wells, or a
target well. The blades in the apparatus 100 may be extended and retracted as
desired, perhaps to secure the position of the tool body 1270 in a more
centralized position in the borehole 1212.
[00'75] The measurement data can be communicated to a surface logging
facility 1292 for processing, analysis, and/or storage. The logging facility
1292
may be provided with electronic equipment for various types of signal
processing, which may be implemented by any one or more of the components
of the system 1000 in FIG. 10. Similar formation evaluation data may be
gathered and analyzed during drilling operations (e.g., during logging while
drilling operations, and by extension, sampling while drilling).
[0076] In some embodiments, the tool body 1270 is suspended in the wellbore
by a wireline cable 1274 that connects the tool to a surface control unit
(e.g.,
comprising a workstation 1254). The tool may be deployed in the borehole 1212
on coiled tubing, jointed drill pipe, hard wired drill pipe, or any other
suitable
deployment technique.
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[0077] Turning now to FIG. 13, it can be seen how a system 1364 may also
form a portion of a drilling rig 1302 located at the surface 1304 of a well
1306.
The drilling rig 1302 may provide support for a drill string 1308. The drill
string
1308 may operate to penetrate the rotary table 1210 for drilling the borehole
1212 through the subsurface formations 1214. The drill string 1308 may include
a Kelly 1316, drill pipe 1318, and a bottom hole assembly 1320, perhaps
located
at the lower portion of the drill pipe 1318.
[0078] The bottom hole assembly 1320 may include drill collars 1322, a
downhole tool 1324, and a drill bit 1326. The drill bit 1326 may operate to
create the borehole 1212 by penetrating the surface 1304 and the subsurface
foimations 1214. The downhole tool 1324 may comprise any of a number of
different types of tools including MWD tools, LWD tools, and others.
[0079] During drilling operations, the drill string 1308 (perhaps including
the
Kelly 1316, the drill pipe 1318, and the bottom hole assembly 1320) may be
rotated by the rotary table 1210. Although not shown, in addition to, or
alternatively, the bottom hole assembly 1320 may also be rotated by a motor
(e.g., a mud motor) that is located downhole. The drill collars 1322 may be
used
to add weight to the drill bit 1326. The drill collars 1322 may also operate
to
stiffen the bottom hole assembly 1320, allowing the bottom hole assembly 1320
to transfer the added weight to the drill bit 1326, and in turn, to assist the
drill bit
1326 in penetrating the surface 1304 and subsurface formations 1214.
[0080] During drilling operations, a mud pump 1332 may pump drilling fluid
(sometimes known by those of ordinary skill in the art as "drilling mud") from
a
mud pit 1334 through a hose 1336 into the drill pipe 1318 and down to the
drill
bit 1326. The drilling fluid can flow out from the drill bit 1326 and be
returned
to the surface 1304 through an annular area between the drill pipe 1318 and
the
sides of the borehole 1212. The drilling fluid may then be returned to the mud
pit 1334, where such fluid is filtered. In some embodiments, the drilling
fluid
can be used to cool the drill bit 1326, as well as to provide lubrication for
the
drill bit 1326 during drilling operations. Additionally, the drilling fluid
may be
used to remove subsurface formation cuttings created by operating the drill
bit
1126.
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[0081] In light of the foregoing discussion, it may be seen that in some
embodiments, the system 1364 may include a drill collar 1322 and/or a
downhole tool 1324 to house one or more systems 1000, including some or all of
the components thereof Thus, for the purposes of this document, the term
"housing" may include any one or more of a drill collar 1322, or a crossover
sub
(see FIG. 1), or a downhole tool 1324 (each having an outer wall, to enclose
or
attach to blades to which magnetometers, sensors, fluid sampling devices,
pressure measurement devices, transmitters, receivers, fiber optic cable,
acquisition and processing logic, and data acquisition systems, are attached).
Many embodiments may thus be realized.
[0082] Thus, referring now to FIGs. 1-10 and 12-13, it may be seen that in
some embodiments, the systems 1264, 1364 may include a drill collar 1322, a
crossover sub (see FIG. 1) as part a downhole tool 1324, and/or a wireline
logging tool body 1270 to house one or more apparatus 100, similar to or
identical to the apparatus 100 described above and illustrated in the figures.
Any
and all components of the system 1000 shown in FIG. 10 may also be housed by
the tool 1324 or the tool body 1270.
[0083] The tool 1324 may comprise a downhole tool, such as an LWD tool or
an MWD tool. The wireline tool body 1270 may comprise a wireline logging
tool, including a probe or sonde, for example, coupled to a logging cable
1274.
Many embodiments may thus be realized, and a list of some of them follows.
Additional Example Embodiments
[0084] In some embodiments, an apparatus comprises a tubular member and at
least two interchangeable blades attached to the tubular member. The blades
are
extendible radially outward to an extended position and retractable radially
inward to a retracted position. The outer surface of the blades is disposed at
or
below an outer surface of the tubular member when the blades are in the
retracted position.
[0085] In some embodiments, the apparatus further comprise a plurality of
sensors forming a portion of the outer surface of the blades, wherein the
sensors
are used to engage a circumferential portion of a borehole wall along the
outer
surface of the blades in an azimuthal direction when the blades are disposed
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downhole in the extended position. The sensors are attached to the blades so
as
to refrain from engaging the borehole wall when the blades are disposed
downhole in the retracted position.
[0086] In some embodiments, the tubular member comprises one of a drilling
collar, a crossover sub, or a bottom hole assembly.
[0087] In some embodiments, the at least two interchangeable blades comprise
identical blades. In some embodiments, sonic of the interchangeable blades
comprise identical blades, and some of the interchangeable blades do not
comprise identical blades.
[0088] In some embodiments, the at least two interchangeable blades comprise
three or four interchangeable blades. In some embodiments, each of the blades
occupies a substantially similar portion of a circumference of the tubular
member when the blades are in the retracted position.
[0089] In some embodiments, each of the blades overlap at least one other one
of the blades along the circumference of the tubular member when the blades
are
in the retracted position. In some embodiments, each of the blades overlap at
least two other blades along the circumference of the tubular member when the
blades are in the retracted position.
[0090] In some embodiments, gears, electromagnetic, piezoelectric, shape
memory alloy, and/or hydraulic actuators are used to couple the tubular member
to the blades.
[0091] In some embodiments, the plurality of sensors comprise at least two
different sensor types arranged on one of the blades. In some embodiments, the
plurality of sensors on each blade are identical. In some embodiments, the
sensors comprise one or more transducers. In some embodiments, the
transducers are attached to a single blade. In some embodiments, each
transducer
is attached to a different blade.
[0092] In sonic embodiments, each of the blades includes end pieces that
engage end pieces of other blades in a mirrored fashion when the blades are in
the retracted position.
[0093] In some embodiments, the outer surface of the blades substantially
conforms to the outer surface of the tubular member, to form a substantially
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complete and continuous outer surface, when the blades are in the retracted
position.
[0094] In some embodiments, one or more (or all) of the blades is attached to
the tubular member at a single point of rotation. In some embodiments, the
single point of rotation comprises an aperture in the blade extending in a
longitudinal direction of the tubular member and located on an interlocking
portion of the blade.
[0095] In some embodiments, each of the blades is formed in a crescent shape.
Some embodiments comprise multiple sets of the at least two interchangeable
blades, each of the sets attached to the tubular member at a different
longitudinal
location. The sets may be arranged to form an array of sonic transducers, or
antennas, for example.
[0096] In some embodiments, a system comprises a controller and an
apparatus operatively coupled to the controller. In some of these embodiments,
the apparatus comprises a tubular member attached to at least two
interchangeable blades, the blades being extendible radially outward
responsive
to receiving an extend command issued by the controller, to an extended
position, and retractable radially inward responsive to receiving a retract
command issued by the controller, to a retracted position. The outer surface
of
the blades is disposed at or below an outer surface of the tubular member when
the blades are in the retracted position. In some embodiments, the outer
surface
of the blades operate to complete the outer surface of the tubular member when
the blades are in the retracted position.
[0097] In some embodiments, the system comprises a plurality of sensors
forming a portion of the outer surface of the blades, wherein the sensors are
to
engage a circumferential portion of a borehole wall along the outer surface of
the
blades in an azimuthal direction when the blades are disposed downhole in the
extended position, and to refrain from engaging the borehole wall when the
blades are disposed downhole in the retracted position.
[0098] In some embodiments, the tubular member comprises a portion of a
drill string, wherein the apparatus operates as a passive stabilizer to
centralize
the drill string when the blades are in the extended position. This
centralizing
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operation may occur when the tubular member is used in a wireline operation,
or
a drilling operation, among others.
[0099] In some embodiments, a method comprises lowering a tubular member
into a borehole while at least two interchangeable blades attached to the
tubular
member are in a retracted position. The blades are retractable radially inward
from an extended position to the retracted position, wherein an outer surface
of
each of the blades is disposed at or below an outer surface of the tubular
member
when the blades are in the retracted position.
[00100] In some embodiments, a method comprises extending the blades
radially outward into the extended position to engage, by the outer surface of
each one of the blades and a plurality of sensors attached to the blades in an
azimuthal direction, a circumferential portion of a wall of the borehole. In
some
embodiments, the plurality of sensors form a portion of the outer surface of
at
least some of the blades in the azimuthal direction.
[00101] In some embodiments, extending the blades further comprises rotating
a geared mechanism or activating an electromagnetic, piezoelectric, shape
memory alloy, or hydraulic actuator attached to the blades.
[00102] In some embodiments, a method comprises measuring a resistance
force encountered by one or more of the blades. The method may further include
ceasing to extend the blades when a preselected amount of the resistance force
is
measured.
[00103] In some embodiments, a method comprises acquiring sensor data from
the plurality of sensors, wherein at least two different sensor types are
located on
at least one of the blades. In some embodiments, the same sensors types are
located on each of the blades.
[00104] In some embodiments, a method comprises retracting the blades
radially inward into the retracted position. In some embodiments, the method
may further include drilling into a geological formation surrounding the
borehole, to extend a length of the borehole, using a drill string that
includes the
tubular member. In some embodiments, the method may further include
extending the blades radially outward into the extended position to stabilize
the
drill string within the borehole. After reading the information disclosed
herein,
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those of ordinary skill in the art will realize that many other embodiments
may
be realized, but in the interest of brevity, these are not listed here.
Conclusion
[00105] In summary, the apparatus, systems, and methods disclosed herein
differ from conventional sensor mounting apparatus in that the sensor-mounted
structures may be fabricated as two, three, or four (or more) blades which are
crescent-shaped. Multiple sensors can be located on each blade to provide
different sensing services at any given circumferential location around the
wall
of the borehole. The blades are interchangeable, so that repairs are
relatively
inexpensive (e.g., a single blade can be replaced, instead of an entire
collar), and
changes in sensing service can be made relatively easily as well.
[00106] Another difference in most embodiments is the mechanism used to
couple the sensors to the borehole wall. Due to the crescent shape of the
blades,
circumferential coupling is provided, rather than point coupling. This
enhances
the connection between the sensor and the formation. The proximity of the
sensor to the borehole wall enable the acquisition of more accurate data,
reducing noise created by the tools and surrounding environment. In short, the
overall construction of the various embodiments provides great flexibility, at
relatively low cost. As a result, the value of services provided by an
operation/exploration company may be significantly enhanced.
[00107] The accompanying drawings that form a part hereof, show by way of
illustration, and not of limitation, specific embodiments in which the subject
matter may be practiced. The embodiments illustrated are described in
sufficient
detail to enable those skilled in the art to practice the teachings disclosed
herein.
Other embodiments may be utilized and derived therefrom, such that structural
and logical substitutions and changes may be made without departing from the
scope of this disclosure. This Detailed Description, therefore, is not to be
taken
in a limiting sense, and the scope of various embodiments is defined only by
the
appended claims, along with the full range of equivalents to which such claims
are entitled.
[00108] Such embodiments of the inventive subject matter may be referred to
herein, individually and/or collectively, by the term "invention" merely for
22
convenience and without intending to voluntarily limit the scope of this
application to any single invention or inventive concept if more than one is
in
fact disclosed. Thus, although specific embodiments have been illustrated and
described herein, it should be appreciated that any arrangement calculated to
achieve the same purpose may be substituted for the specific embodiments
shown. This disclosure is intended to cover any and all adaptations or
variations
of various embodiments. Combinations of the above embodiments, and other
embodiments not specifically described herein, will be apparent to those of
skill
in the art upon reviewing the above description.
[00109] The Abstract of the Disclosure is provided allow the reader to quickly
ascertain the nature of the technical disclosure. It is submitted with the
understanding that it will not be used to interpret or limit the scope or
meaning
of the claims. In addition, in the foregoing Detailed Description, it can be
seen
that various features are grouped together in a single embodiment for the
purpose of streamlining the disclosure. This method of disclosure is not to be
interpreted as reflecting an intention that the claimed embodiments require
more
features than are expressly recited in each claim. Rather, as the following
claims
reflect, inventive subject matter lies in less than all features of a single
disclosed
embodiment. Thus the following claims each stand on its own as a separate
embodiment.
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