Note: Descriptions are shown in the official language in which they were submitted.
INSTRUMENTED WELLBORE CABLE
AND SENSOR DEPLOYMENT SYSTEM AND METHOD
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This disclosure is a continuation-in-part application of U.S. Serial
No. 14/639,541,
filed March 5, 2015, the entirety of which is incorporated herein by reference
for all
purposes.
FIELD OF THE INVENTION
[0002] The present invention generally relates to deployment of instrument
cables and
control lines in an oil and gas wellbore. Specifically, the present invention
provides a
system and method for rapid deployment of fiber optic sensors and distributed
sensing
cables, electronic sensors and conventional electronic cables, capillary
tubing, or hydraulic
control lines in the annulus of a wellbore along a specific well zone without
the need to
clamp cables to the casing or tubing string for support.
PRIOR ART AND BACKGROUND OF THE INVENTION
Prior Art Background
[0003] Economic challenges have created the necessity for increased efficiency
and
precision of hydrocarbon production methods. Deploying instruments into the
wellbore
that capture data from specific zones can help achieve these efficiencies.
[0004] Advancements in distributed fiber optic sensing ("DxS") technologies
have
resulted in such technologies becoming economically competitive with
conventional
logging methods. The barrier to wider use of DxS and other down-hole
instruments by
well operators has been relatively high installation costs.
[0005] In most cases, the standard casing program does not provide adequate
clearance
for current cable installation. This necessitates upsizing the entire casing
and wellbore
program to accommodate the necessary fiber cables, "marker" cables and
associated
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clamps or centralizers that are run on the outside of the casing. The costs
associated with
drilling larger diameter wellbores can range from $500,000 to over $1 million,
per well,
in addition to the rig time for placement of clamps and centralizers.
[0006] The current industry practice for deploying instrumented cables and
control lines
behind casing or in the casing-tubing annulus is to rigidly attach the cables
to the casing
or tubing with bands or clamps that support the weight of the cable and
deliver it down-
hole. These clamps or bands may increase the outer running diameter of the
casing string,
which may necessitate upsizing of the well-bore to provide sufficient running
clearance
and reduce the risk of cable damage during installation transit.
[0007] While running these types of completions, the casing or tubing cannot
be rotated
without potential damage to the cables or control lines. The cables and
control lines are
typically installed from spools located some distance away from the rig. A
cable sheave is
then suspended above the rig floor to guide and position the cable relatively
parallel to the
casing or tubing so that it can be manually clamped into place. The suspended
sheave load
above the rig floor creates a potential safety hazard from failure of the
suspending means
and the load falling on rig personnel.
[0008] It may also be desirable during the drilling phase of a well to
temporarily run
certain fiber optic or electronic sensors into the annular space between the
wellbore and
drill pipe to better obtain geophysical parameters. Conventional logging
systems are
typically run inside the drill pipe which may act as an insulator and
attenuate some sensor
signals causing erroneous or weak signals.
Deficiencies in the Prior Art
[0009] The prior art as detailed above has the following deficiencies:
= Prior art systems present a safety hazard to workers on the rig floor due
to heavy
loads comprising cable sheaves to be suspended above the rig floor.
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= Prior art systems do not provide for rotation of the casing or tubing
without the risk
of damaging the sensor cable.
= Prior art systems require use of bands or clamps to rigidly attach
instrument cables
to the outside of the casing which many times requires drilling a larger
diameter
wellbore and thus increasing operational costs and drilling time.
= The prior art systems require labor-intensive efforts to manually attach
the
instrument cables to the casing thus increasing labor costs and drilling
times.
= The prior art systems involve the expense of upsizing wellbores to
accommodate
the bands or clamps on the casing exterior.
= Prior art systems are typically not run during the drilling phase of well
construction
due to the time, expense, and risks associated with clamping or banding cables
to
the drill pipe.
[0010] While some of the prior art may teach some solutions to several of
these problems,
the core issue of using a system of distributed fiber optic sensing technology
within a
durable and rugged delivery means to gather well logging data is disclosed as
a way to
deliver high quality information at lower cost to energy professionals.
OBJECTIVES OF THE INVENTION
[0011] Accordingly, the objectives of the present invention are (among others)
to
circumvent the deficiencies in the prior art and affect the following
objectives:
= Utilize a unique type of ruggedized sensor cables with sufficient tensile
and crush
strength to run between the casing and bore-hole, which can be cemented in
place,
and be used to gather well logging data.
= Eliminate or reduce the need to up-size a wellbore to accommodate cables
and
sensors.
= Provide for positioning of distributed fiber optic sensing means that
could be
installed or removed in a feasible, economic, and timely manner.
= Provide a ruggedized cable of composite construction utilizing multiple
reduced
outside diameter sensor cables within a protective polymer sheath for impact
resistance; lined with a low-friction polymer on the casing side, to reduce
potential
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twisting during casing rotation; and lined with metal sheath on the wellbore
side
that is crimped onto the polymer and cables to prevent separation.
= Other concepts are to use full encapsulation with dual-polymer extrusion
with low-
friction surface, combinations of polymers with high-strength composite
materials
such as carbon fiber and steel, or full metal encapsulation in a "flat-pack"
arrangement with welded seams.
= Provide for increased running speeds and reduced manpower and rig-time
needs by
eliminating rigid casing clamps at each pipe joint.
= Provide for self-supporting, ruggedized instrument cable by installing
rotating cable
hangers at strategic intervals which results in achieving near normal run-
rates
during casing deployment and makeup.
= Provide for rotation of the casing string through tight spots, eliminate
or reduce the
need for reamer runs, and improve cementing efficiency where reciprocation is
required. The rotating casing hangers allow free rotation movement of the pipe
and
may (or may not) provide some limited axial movement of the casing with the
hangers.
= Providing a system of metal sheathing or encapsulation in the composite
construction to induce a high magnetic flux signature and allow use of
existing
magnetic mapping tools when required. Such magnetic flux may be increased by
adding Ferro-magnetic particles to the encapsulating polymer matrix.
= Providing a system compatible with conventional plug and perforation
completions,
conventional frack sleeve systems, and swell packers.
= Provide a system that increases the safety of personnel during running
operations
100121 While these objectives should not be understood to limit the teachings
of the
present invention, in general these objectives are achieved in part or in
whole by the
disclosed invention that is discussed in the following sections. One skilled
in the art will
no doubt be able to select aspects of the present invention as disclosed to
affect any
combination of the objectives described above.
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BRIEF SUMMARY OF THE INVENTION
System Overview
[0013] The present invention, in various embodiments, provides a system and
method to
provide rapid deployment of fiber optic sensing cables, conventional
electronic cables, or
hydraulic control lines in the annulus of a wellbore without the need to clamp
cables to the
casing or tubing string for support, the system comprising:
A cable anchor sub-assembly;
Cable carriers;
Ruggedized cable; and
Specialized surface deployment equipment.
The method in broad aspect is the use and activation of the apparatus as
described.
Method Overview
[0014] The present invention system may be utilized in the context of an
overall resource
extraction method, wherein the instrumented wellbore cable and sensor
deployment
system described previously is controlled by a method having the following
steps:
(I) installing the wellbore casing to the proper depth;
(2) deploying the flexible polymer cable along with anchor subassembly and
intermediate cable carriers to the target location in the wellbore;
(3) connecting sensor or communication cables embedded in flexible polymer
cable to surface equipment;
(4) confirming flexible polymer cable is deployed to target location in
wellbore;
(5) energizing the sensors and gather geophysical data;
(6) performing well stimulation such as acidizing or fracturing, if
required;
(7) checking if all data has been collected, if not, proceeding to step
(2); and
(8) pumping or flowing the resource from the well;
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[0015] Integration of this and other preferred exemplary embodiment methods in
conjunction with a variety of preferred exemplary embodiment systems described
herein
in anticipation by the overall scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a fuller understanding of the advantages provided by the invention,
reference
should be made to the following detailed description together with the
accompanying
drawings wherein:
[0017] FIG. 1 is a cross-section view depicting an exemplary embodiment of the
instrumented wellbore cable 5 deployed in a borehole 1.
[0018] FIG. 2 is a schematic side-view of alternative arrangements of an
exemplary
embodiment of the invention depicting a bow-spring arm carrier 11, a semi-
circular spring-
loaded carrier 12, and a spring-loaded rocker arm carrier 13.
[0019] FIG. 3 illustrates a plan view of an exemplary embodiment of the bow-
spring arm
carrier 11.
[0020] FIG. 4 illustrates a plan view of an exemplary embodiment of the semi-
circular
spring-loaded carrier 12.
[0021] FIG. 5 illustrates a plan view of an exemplary embodiment of the spring-
loaded
hinged arm carrier 13.
[0022] FIG. 6 illustrates an operational side view of an alternative exemplary
embodiment
of a cable anchor sub-assembly 14 situated on casing 3 within the wellbore I.
The figure
depicts the flexible polymer cable 5 attached to the anchor sub-assembly 14 by
means of
a cable clip 15.
[0023] FIG. 7 illustrates an operational side view of the bow-spring carrier
II of the
apparatus shown in Figure 3 depicting the carrier 20 and cable clip 15,
without the cable
5.
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[0024] FIG. 8 illustrates an operational side view of an embodiment of a
hinged cable
carrier 27 depicting the flexible polymer cable 5 attached to a cable clip 21
which is
attached to a hinged cable carrier 27 fabricated to allow the casing 1 to
rotate through the
longitudinal axis of the hinged cable carrier 27 without exerting rotational
force to the
cable 5. The cable clip 21 is attached to the carrier 27 by an upper hinged
bracket 28 and
a lower hinged bracket 29. These brackets allow a small degree of mobility in
movement
of the flexible polymer cable 5.
[0025] FIG. 9 illustrates an operational flowchart of a preferred exemplary
embodiment
of a method of using the invention.
[0026] FIG. 10 illustrates an operational view of an embodiment of the cable
feeder
assembly 10 depicting the articulating hydraulic arm 16 and cable spool 17
mounted on a
flatbed trailer situated adjacent to a drilling rig 19.
[0027] FIG. 11 illustrates an enlarged operational view of an embodiment of
the
articulating hydraulic arm 16 attached to the drilling rig 19.
[0028] FIG. 12 illustrates an enlarged operational view of an embodiment of
the
articulating hydraulic arm 16 attached to the drilling rig 19 where the
flexible polymer
cable 5 feeds down to the wellbore 1.
[0029] FIG. 13 illustrates one embodiment of a cable carrier orientation
system having a
weighted cable orientation subsystem in accordance with the disclosed
principles.
[0030] FIG. 14 illustrates another embodiment of a cable carrier orientation
system having
a weighted cable orientation subsystem in accordance with the disclosed
principles.
[0031] FIG. 15A illustrates one embodiment of a cable carrier orientation
system having
a weighted cable orientation subsystem and employing bow springs as
centralizing
devices.
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[0032] FIG. 15B illustrates a perspective view taken from one end of the cable
carrier
orientation system shown in FIG. 15A.
[0033] FIG. 16 illustrates another embodiment of a carrier orientation system
in
accordance with the disclosed principles, and which employs the weight of the
casing to
automatically orient the rotational position of the parameter detecting
device.
[0034] FIG. 17 illustrates another embodiment of a carrier orientation system
having
eccentrically oriented carriers and casing in accordance with the disclosed
principles.
[0035] FIG. 18 illustrates one embodiment of a carrier orientation system in
accordance
with the disclosed principles in combination with a position reporting device.
[0036] FIG. 19 illustrates one embodiment of a carrier orientation system
using an active
positioning system in accordance with the disclosed principles.
[0037] FIG. 20 illustrates another embodiment of a carrier orientation system
using an
active positioning system in accordance with the disclosed principles.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS
[0038] While this invention is susceptible of embodiment in many different
forms, there
is shown in the drawings and will herein be described in detailed preferred
embodiment of
the invention with the understanding that the present disclosure is to be
considered as an
exemplification of the principles of the invention and is not intended to
limit the broad
aspect of the invention to the embodiment illustrated.
[0039] The numerous innovative teachings of the present application will be
described
with particular reference to the presently preferred embodiment, wherein these
innovative
teachings are advantageously applied to the particular problems of an
instrumented
wellbore cable and sensor deployment system and method. However, it should be
understood that this embodiment is only one example of the many advantageous
uses of
the innovative teachings herein. In general, statements made in the
specification of the
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present application do not necessarily limit any of the various claimed
inventions.
Moreover, some statements may apply to some inventive features but not to
others.
[0040] The present invention is an improved instrumented wellbore cable and
sensor
deployment system and method to gather data from areas of interest in the rock
formation
surrounding a wellbore by using an instrumented cable that is not rigidly
attached to the
casing at every joint. The apparatus allows rotation of the casing to improve
running and
cementing, and allows use of existing magnetic orienting tools for cable
location,
eliminates the need for cable sheaves hanging about the rig floor, and
comprising;
(a) A flexible polymer cable with embedded wires,
(b) A system for deploying said flexible polymer cable,
(c) A means to hold the flexible polymer cable along a casing wall surface
to
allow sensing of at least one wellbore parameter.
Wherein
The system is configured to coaxially fit within a wellbore;
The system is configured to provide an articulating hydraulic arm to deploy
the
cable and sensors from a cable spool to the drilling rig and down into the
wellbore;
The system is configured to allow rotation of the wellbore casing or tubing
within
the longitudinal axis of cable carriers; and
The anchor subassembly and the intermediate cable carriers are configured to
support the weight of the flexible polymer cable in the downhole environment.
This general system summary may be augmented by the various elements
described herein to produce a wide variety of invention embodiments consistent
with this
overall design description.
Detailed Description of the Preferred Embodiments
[0041] Referring to Figure 1, a flexible polymer cable 5 in accordance with
one preferred
embodiment is shown deployed in a wellbore 1. As generally illustrated in
Figure 1, a
casing 3 is deployed in a borehole with a ruggedized flexible polymer cable 5
situated
adjacent to the wellbore 1 and surrounded by cement 2. The flexible polymer
cable 5
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comprises a plurality of sensor cables 9 (which may include fiber optic
cables, electric
control lines, or hydraulic control lines) with reduced outside diameter,
embedded in an
erosion resistant polymer 8, which is itself surrounded by a low-friction
polymer 6. A
metal sheath 7 is situated around the low-friction polymer 6 outside surface
in such way
as to protect the cable 5 from abrasive contact with the wellbore 1.
[0042] According to one aspect of a preferred exemplary embodiment, cable 5
may be
deployed at desired locations to acquire geophysical information from the
surrounding
formation without the need for clamping the cable 5 to the wellbore casing 3.
[0043] Cable 5 may have different types of electronic or optical sensors 9
attached to or
imbedded in the cable at various intervals for acquiring geophysical
information.
[0044] According to another preferred exemplary embodiment, cable 5 is fully
encapsulated with low-friction polymer extrusion 6 on one side for casing
friction drag
reduction, or full metal 7 encapsulation in a "flat-pack" arrangement with
welded seams.
[0045] According a further preferred exemplary embodiment and referring to
Figure 2,
cable 5 is not rigidly clamped to the wellbore casing 3 at each joint, leading
to faster
completions and reduced rig-time and manpower otherwise used to clamp sensor
cables 5
to each casing 3 joint. By installing rotating cable hangers at strategic
intervals the cable
is self-supporting in the vertical section of the wellbore 1 and near normal
run-rates for
casing 3 makeup and deployment are achieved. Allowing rotation of the casing
string 3
eliminates or reduces the need for reamer runs, and casing 3 can be rotated
through tight
spots, improves cementing 2 where reciprocation is required. The rotating
casing hangers
11, 12, 13 allow free rotational movement of the pipe and may provide limited
axial
movement of the casing 3 with the hangers 11, 12, 13.
[0046] According to yet another preferred exemplary embodiment, cementing the
ruggedized cable 5 in place between the casing and the wellbore 1 eliminates
or reduces
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the need for larger wellbore 1 diameter. Furthermore, integrating metal
sheathing or Ferro-
magnetic particles into the polymer matrix 6, 8 creates high magnetic flux
signature for
the cable 5, and allows the cable 5 to be located with existing magnetic
mapping tools.
Locating the the relative orientation of the cable allows perforating guns to
be configured
to shoot unidirectionally (instead of the typical 360 degree pattern), and
avoid the cable 5
by firing the perforation guns away from the relative bearing of the cable 5.
Preferred Exemnlary instrumented wellbore cable and sensor deployment method
Flowchart
[0047] As generally seen in the flow chart of Figure 9, a preferred exemplary
instrumented wellbore cable and sensor deployment method may be generally
described
in terms of the following steps:
(1) installing the wellbore casing to the proper location in the wellbore
(0901);
(2) deploying the flexible polymer cable with the anchor subassembly in
wellbore (0902);
(3) deploying intermediate cable carriers as needed (0903);
(4) connecting the sensor or communication cables embedded in the flexible
polymer cable to surface equipment (0904);
(5) confirming the flexible polymer cable is deployed to the target
location in
the wellbore (0905);
(6) energizing the sensor or communication cables and gathering geophysical
data from the target location in the wellbore (0906);
(7) perform well stimulation, as needed (0907);
(8) Pumping and flowing the resource from the well (0908).
Preferred Embodiment Side View Cable Support Carriers
[0048] Yet another preferred embodiment may be seen in more detail as
generally
illustrated in Figures 2, 3, 4 and 5, wherein cable support carriers 11, 12,
13 are slipped
over the outside of casing 3 with sufficient gap to allow casing 3 to rotate
and/or
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reciprocate inside the carrier 11, 12, or 13, while holding the cable 5
stationary relative to
the borehole 1.
[0049] Figure 3 depicts a plan view of a bow-spring arm carrier 11 and bow-
spring arm
20 positioned over the casing 3 and holding the cable 5 adjacent to the
borehole. The bow-
spring carrier 11 is free to slide along the casing 3 and allows casing 3 to
rotate while the
bow-spring arm 20 holds the cable adjacent to the wellbore 1.
[0050] Figure 4 depicts plan view of a spring-loaded longitudinally hinged arm
carrier 12
positioned over the casing 3 and holding the cable 5 adjacent to the borehole.
The hinged-
arm carrier 12 is free to slide along the casing 3 and allows casing 3 to
rotate while the
hinged arm carrier 12 holds the cable adjacent to the wellbore 1.
[0051] Figure 5 depicts plan view of a spring-loaded hinged arm carrier 13
positioned
over the casing 3 and holding the cable 5 adjacent to the borehole. The spring-
loaded
hinged arm carrier 13 is free to slide along the casing 3 and allows casing 3
to rotate while
the spring-loaded hinged arm carrier 13 holds the cable adjacent to the
wellbore I.
Preferred Embodiment Side View of an Anchor Sub-Assembly
[0052] Figure 6 depicts a preferred embodiment wherein an anchor subassembly
14 is
shown downhole in place over the outer surface of a wellbore casing 3. Said
subassembly
14 includes a cable clip 15 used to secure the flexible polymer cable 5 to the
subassembly
14. The subassembly 14 is slipped over the casing joint 3 at the surface and
the
instrumented flexible polymer cable 5 is attached to the subassembly 14 before
it is
transited the wellbore 1 to the desired location.
[0053] Figure 7 depicts another preferred exemplary embodiment wherein a bow-
spring
carrier 11 is shown without the cable 5. In the downhole environment, the bow-
spring
carrier 11 places the instrumented cable 5 adjacent to the wellbore wall 1
with the cable 5
secured in a cable clip 15 attached to the bow-spring arm 20. The bow-spring
carrier 11 is
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fabricated to allow the casing 3 to easily rotate through the subassembly 14
without
applying rotational force to the cable 5. A plurality of bow-spring arms 20
are situated
around the bow-spring carrier 11 to strengthen the centralizing action and
provide an
attachment point for the cable 5.
[0054] In a preferred embodiment, only a few of the bow-spring carriers 20
would be
deployed downhole in the casing string 3, thus minimizing rig-time for
installation. After
a completed installation to the desired location, the instrumented cables 5
can be
terminated at surface points using conventional ported hangers and wellhead
exits.
[0055] In another preferred embodiment shown in Figure 8, the flexible polymer
cable 5
is attached to a cable clip 21 which is attached to a hinged cable carrier 27
that is situated
in a downhole environment. The hinged cable carrier 27 is fabricated to allow
the casing
3 to rotate through the longitudinal axis of the carrier 27 without exerting
rotational force
to the cable 5. The cable clip 21 is attached to the carrier 27 by an upper
hinged bracket
28 and a lower hinged bracket 29. These brackets allow a small degree of
mobility in the
movement of the flexible polymer cable 5 in the downhole environment.
[0056] Also, for down-hole installation of fiber optic cabling or other
parameter detecting
sensors/devices used for distributed sensing, and for discrete sensors such as
seismic
transducers or pressure-temperature sensors, there can be benefits to placing
the cable or
sensor at a particular rotational angle within the wellbore. An example of
this could be for
placing fiber optic cable or seismic sensors along the upper-most point of a
horizontal
wellbore to eliminate shadowing effects of the metal casing and thereby
increase
sensitivity to surface generated seismic sources. An additional benefit of
predetermining
the orientation of a cable or instruments within the wellbore is for uniform
placement of
sensors and the potential ambiguity between readings of multiple sensors at
different
depths that may be caused by non-uniform placement.
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[0057] Unfortunately, existing systems for instrument and cable deployment on
a wellbore
tubing or casing do not include methods to selectively position the
instruments or cable in
a predetermined rotational orientation within the wellbore. Methods such as
magnetic
detection or acoustic logging must be used after the cable or instruments are
installed to
"find" the cable (i.e., map the relative bearing) so that perforating charges
can be aimed
away from the cable or instruments in order to avoid damaging the cable or
instruments.
The time and expense required to map the cable with the logging tools is
considerable, and
often times these tools do not accurately locate a cable resulting in damaged
cable during
the perforation event. Thus, it would also be advantageous to have a system
that positions
the cable at a planned orientation within wellbore to reduce or eliminate the
need for
locating or "mapping" tools before perforating. The same advantages would be
beneficial
in a system where the position of a different parameter detecting device,
other than a cable,
can be determined.
[0058] To address these deficiencies, the disclosed principles also provide
for the
inclusion of passive or active systems that place the cable, or other
parameter detecting
device, and the carriers at a predetermined rotational position within the
wellbore during
deployment. For example, tubing or casing can rotate within the carrier
supports and
subassemblies discussed herein, and thus are somewhat free to rotate with the
wellbore
during running. If the parameter detecting device is a cable, cable tension
may be applied
to help insure the cable remains fairly linear during deployment, but
perforating the well
still requires mapping with a magnetic or acoustic logging tool to insure
perforations are
oriented away from the cable or other parameter detecting device. Thus, the
disclosed
principles provide for carrier orientation systems for use with the carriers
that are capable
of turning a section of the carrier towards a predetermined or desired
rotational position
with the wellbore. For example, gravity-based carrier orientation systems can
be used to
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rotate the carriers around the casing and towards the direction of maximum
gravitational
pull. As such, the applied motive (turning) force assures that the carrier
seeks a known or
desired orientation as it slides along the wellbore (i.e., the turning
overcomes friction to
rotate the carrier around the casing as it moves inside the wellbore).
[0059] One technique to passively accomplishing this is with a either, or a
combination
of, weights and/or buoyant devices to allow the automatic rotational orienting
of the
carrier, and ultimately the cable or other parameter detecting device, to a
known position
depending on how and where it is attached to the carrier.
[0060] Looking at Figure 13, illustrated is one embodiment of a carrier
orientation system
having a weighted orientation subsystem in accordance with the disclosed
principles. In
this embodiment, the carrier orientation system includes a buoyancy device 22,
as well as
weighting device 23. As illustrated, the buoyancy device 22 and weighting
device 23 are
located on opposing outer sides of the carrier 11, approximately 180 degrees
apart. As
discussed above, the carrier 11 is configured to rotate independently of the
casing 3. As
such, as the casing 3 is deployed into a non-vertical wellbore 1, the
weighting device 23,
which is connected to the carrier 11, will rotate downwards in the direction
of the
gravitational pull of the earth. Consequently, since the orientation of the
fiber optic cable
5, which is also attached to the carrier 11, is known prior to deployment into
the wellbore
1 in relation to the position of the weighting device 23 on the carrier 11,
the position of the
cable 5 can be determined with specificity throughout the lengths of the
wellbore 1. Also,
the buoyancy device 22 may also, or alternatively, be attached to the carrier
11 for use
when the wellbore hole 2 is filled with water or other fluid. Specifically,
the buoyancy
device 22 is selected to be buoyant within such fluid, which will then result
in the buoyancy
device 22 "floating" to the top of a non-vertical wellbore hole 2. As the
buoyancy device
22 floats to the top of the non-vertical wellbore hole 2, it will cause the
carrier 11 to rotate
CA 3044444 2019-05-28
into a specific position, and consequently cause the fiber cable 5 to be held
into a known
orientation within the wellbore 1.
[0061] The use of either or both of the buoyancy device 22 or weighting device
23 on the
carriers 11 may also be employed in systems employing other types of parameter
detecting
devices other than a communication cable 5. For example, the parameter
detecting device
may be comprised of a seismic sensor capable of detecting seismic activity, a
pressure
sensing device capable of determining pressure within at least a portion of
the wellbore,
or a temperature sensing device capable of determining temperature within at
least a
portion of the wellbore, or an acoustic device capable of emitting acoustic
waves for use
in determining at least one parameter within at least a portion of the
wellbore.
[0062] Another embodiment of a carrier orientation system as disclosed herein
would be
to have the cable 5 itself that is designed to have relatively negative,
neutral, or positive
buoyancy in the wellbore fluids. Specifically, the cable itself, or other
parameter detecting
device, comprises the weighting device, the buoyancy device, or both. For
example, a
buoyant cable can be employed in one embodiment and would assist the carriers
11 in
maintaining a linear alignment along the top of a deviated or horizontal
wellbore. In
addition, a distributed fiber sensing cable that is "floating" (i.e., buoyant)
along the top of
a deviated or horizontal wellbore is inherently more sensitive to formation
parameters with
improved coupling and response to thermal, acoustic, seismic or other types of
measurements. A negative buoyancy cable could alternatively be employed, which
would
lay on the bottom of a deviated or horizontal wellbore and can be more
sensitive to
temperature fluctuations or noise generated by fluids flowing in the wellbore.
For
deployment of a cable along the side of a deviated wellbore, a neutrally
buoyant cable(s)
could be attached to the carrier 11 and would provide a means to assure the
cable 5 is
primarily positioned and held in place by the cable carrier guides. Each of
these
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implementations may also be achieved with other types of parameter detecting
devices
aside from a cable 5.
100631 Turning to Figure 14, illustrated is another embodiment of a carrier
orientation
system having a weighted orientation subsystem in accordance with the
disclosed
principles. In this embodiment, a buoyancy device 22 and weighting device 23
may again
be included and connected on opposing sides of the cable carrier 11. In other
embodiments, only one of the buoyancy device 22 or the weighting device 23 may
be
employed on the carrier 11. Accordingly, these devices 22, 23 can provide the
known
orientation of the fiber cable 5 as described above. Also, such a carrier
orientation system
may be used to determine the rotational position of other types of parameter
detecting
devices. However, this embodiment also includes centralizing devices 24
attached to the
carrier 11. While four centralizing devices 24 are illustrated, a greater or
lesser number of
centralizing devices 24 may also be employed. These centralizing devices 24
are sized to
contact the wellbore wall 1 as the casing 3 and carrier 11 are deployed into
the wellbore 1.
More specifically, the centralizing devices 24 can be made of substantially
equal widths
extending from the carrier 11. As such, as the carrier 11 rotates around the
casing 3 with
the assistance of the buoyancy device 22 and/or the weighting device 23, the
centralizing
devices 24 will keep the casing 3 and carrier 11 substantially concentric
within the
wellbore wall I. Therefore, the width of each of the centralizing devices 24
may be
selected so that the carrier 11 is still permitted to rotate within the
wellbore 1, while still
keeping the carrier 11 and casing 3 substantially concentric. The centralizing
devices 24
may be comprised of blades, bow springs, rollers, or any other structure
capable of
assisting in keeping the carrier 11 substantially concentric within the
wellbore 1, while still
permitting the rotational orientation of the carrier 11.
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[0064] Turning to Figure 15A, illustrated is one embodiment of a carrier
orientation
system having a weighted orientation subsystem, and employing bow springs as
centralizing devices. In this embodiment, a buoyancy device 22 and weighting
device 23
are again included and connected on opposing sides of the carrier 11, and thus
can provide
the known orientation of the fiber cable (not illustrated) or other parameter
detecting
device as described above. Also in this embodiment, a clip 15 may be included
to hold
the fiber cable or other parameter detecting device in a known orientation on
the carrier
11. This embodiment also includes bow springs as the centralizing devices 24
attached to
the carrier 11. As before, while four bow springs 24 are illustrated, a
greater or lesser
number of such centralizing devices may also be employed. These bow springs 24
are
again sized to contact the wellbore wall (not illustrated) as the casing 3 and
carrier 11 are
deployed into the wellbore, while still permitting rotation of the carriers 11
around the
casing 3 as biased by the carrier orientation system.
[0065] Looking now at Figure 15B, illustrated is a perspective view taken from
one end
of the carrier orientation system shown in Figure 15A. From this perspective
view, the
structure and shape of the bow springs 24 operating as the centralizing
devices may better
be seen. In addition, the location and orientation of the clip 15 on the
casing 3 may also
be seen. As with the embodiments discussed above, as the carrier 11 rotates
around the
casing 3 with the assistance of the buoyancy device 22 and/or the weighting
device 23, the
bow springs 24 will keep the casing 3 and carrier 11 substantially concentric
within the
wellbore wall. Therefore, the width of each of the bow springs 24 may be
selected so that
the carrier 11 is still permitted to rotate within the wellbore, while still
keeping the carrier
11 and casing 3 substantially concentric.
[0066] Turning now to Figure 16, illustrated is another embodiment of a
carrier
orientation system in accordance with the disclosed principles, and which
employs the
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weight of the casing to automatically orient the rotational position of the
parameter
detecting device. In this embodiment, the diameter of the casing 3 (and thus
the carriers
11) is laterally offset by a predetermined amount, as illustrated. In an
advantageous
embodiment, the offset amount is substantially equal to the outer dimensions
of the carrier
11; however, other offset amounts may also be employed. By laterally
offsetting the
casing 3, the weight of the casing 3 can be employed as the weighting device
such that the
offset side (i.e., the left side of the casing 3 in FIG. 16) of the casing 3
is drawn in the
direction of gravitational pull by the sheer weight of the casing 3 itself.
Since this is the
case in non-vertical wellbores 1, the cable 5 or other parameter detecting
device can be
located on a chosen side of the carrier 11 such that its location will be
known as the
eccentric casing 3 is drawn downward and the thus the carrier 11 rotates to a
known
position around the casing 3. In application, as the casing 3 and carriers 11
are slid into
the wellbore 1, the weight of the eccentric casing 3 causes the carriers 11 to
rotate towards
the pull of gravity, thereby automatically orienting the rotational position
of the parameter
detecting devices into the desired position. For example, a 40 foot joint of 5
IA inch casing,
which can each have a carrier 11 there on holding the cable 5 or other
parameter detecting
device, can have a weight of approximately 23 pounds per linear foot. Thus,
each 40 foot
joint would weigh about 920 lbs. Thus, the high weight of each joint of casing
3 would
bias each carrier 11 towards the pull of gravity. Additionally, stabilizing
devices 24 may
be employed similar to the centralizing devices discussed above, but sized so
as to maintain
the eccentric orientation of the carriers 11 and casing 3. As before, these
stabilizing
devices 24 may be comprised of any of a number of structures, such as bow
springs, blades
or rollers, or any other advantages structures. The combination of these
structural features
will force the orientation of the carrier 11 with respect to the casing 3 to a
specific position,
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CA 3044444 2019-05-28
which in turn causes the cable 5 or other parameter detecting device(s) to a
known location
or rotational orientation.
[0067] Looking now to Figure 17, illustrated is another embodiment of a
carrier
orientation system having eccentrically oriented carriers and casing in
accordance with the
disclosed principles. In this embodiment, the carrier orientation system
includes the
addition of a buoyancy device 22 and a weighting device 23 in combination with
the offset
casing 3. As illustrated, the carriers 11 and casing 3 are vertically offset
due to the
movement of the heavy casing 3 in the direction of gravitational pull.
Specifically, the
downward offset of the casing 3 causes the weight of the offset side of the
casing 3 to self-
orient the carrier 11 towards the pull of gravity. This is in addition to the
draw of the
weighting device 23 also towards the pull of gravity, and thus the weight of
the casing 3
and the weighting device 23 work together to automatically orient the location
of the
carrier 11, and thus the cable 5 or parameter detecting device(s). Moreover,
the opposing
location of the buoyancy 22 from the weighting device 23 further assists the
rotational
movement of the carrier 11 (in this case in the direction opposite to the pull
of gravity),
and thus further assists the automatic orientation of the cable 5 or other
parameter detecting
device. It should also be noted that in these embodiments, the cable 5 or
other parameter
detecting device may itself be one or both of the buoyancy device 22 or the
weighting
device 23 rather than separate buoyancy and/or weighting devices.
[00681 Turning now to Figure 18, illustrated is one embodiment of a carrier
orientation
system in accordance with the disclosed principles in combination with a
position
reporting device. Specifically, beacons or other devices are available to
transmit its
rotational position within a wellbore. Such beacons or other devices may thus
be placed
proximate to the communication cable 5 or other parameter detecting device, as
illustrated,
to transmit the location of the parameter detecting device. However, this
information alone
CA 3044444 2019-05-28
is not sufficient if the transmitted location of the parameter detecting
device is actually in
an undesirable location, such as where a charge needs to be detonated. Thus,
any of the
carrier orientation systems in accordance with the disclosed principles may be
employed
with such beacons or similar location information providing devices to confirm
that the
location or rotational position of the cable of other parameter detecting
device is where it
is desired using a disclosed carrier orientation system.
[0069] In addition to the carrier orientation systems discussed above, other
embodiments
in accordance with the disclosed principles could include an active, as
opposed to passive,
system for actively adjust the orientation of the carriers 11, and thus the
cable 5 or other
parameter detecting device, after the casing 3 and carriers 11 have been
deployed in a
wellbore I. Looking at Figure 19, illustrated is one embodiment of a carrier
orientation
system using an active positioning system in accordance with the disclosed
principles.
Embodiments of such an active positioning system would use a powered system on
or
within the cable carriers 11 that would be capable of turning the carrier(s)
11 within the
wellbore 1 to the desired orientation. Actuators, such as electric or
hydraulic motors,
electrical solenoids, hydraulic pistons, and/or other powered devices could be
used to
apply a rotational force to the carrier 11 by applying wheels, pads, slips, or
other types of
gripping devices either against the casing 3 or the wellbore wall 1.
[0070] For example, in the embodiment illustrated in Figure 19, the active
system may
include a motor and positioning logics module 25. The logics module 25 would
include
the circuitry and instruments for determining and providing the positioning
information of
the carrier 11, and in turn the location and rotational position of the cable
or other
parameter detecting device. In addition, the logics module 25 may also include
the motor
or other actuator used to provide the positioning of the carrier 11. The
illustrated active
positioning system also includes a drive wheel or gear 26 powered by the
actuator. In this
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CA 3044444 2019-05-28
embodiment, the drive wheel 26 has its contact surface with the exterior of
the casing 3.
As the actuator turns the drive wheel 26, the wheel 26 actively adjusts the
rotational
position of the carrier 11 with respect to the casing 3. As this rotational
position is
adjusted, in either direction, the logics module 25 determines the positioning
between the
two and can provide that information to a user via a control terminal,
application, or other
means of display to the user. The user may then not only determine the precise
position
of the cable 5 or other parameter detecting device, but can adjust that
location in any
direction as needed. Also as illustrated, the powered system may again include
centralizing devices 24 or other sized stabilizing devices for assisting with
positioning of
the carrier 11 and casing 3 within the wellbore 1.
[0071] The power source for the carrier 11 could be electrical power provided
from the
cable 5 or other parameter detecting device(s), or alternatively from on-board
batteries,
hydraulic power from control lines, or other means. Sensors within or attached
to the
carrier I lor the logics module 25, such as gravity or other directional
sensors, could also
be employed to provide the signals to determine the amount of orientation
correction
needed to reposition the carrier 11 using the power actuators. The use of
directional
sensors, such as gyroscopic sensors, accelerometers, electronic compass
sensor, and
others, could be used to automatically provide correction signals to the power
section of
the carrier 11 when gravity-based sensors are not operable or applicable, such
as in true
vertical wells. Beacons, such as those locational beacons or similar devices
discussed
above, could also be employed to provide precise location of the carrier 11
and/or the
parameter detecting device(s).
[0072] Turning to Figure 20, illustrated another embodiment of a carrier
orientation
system using an active positioning system in accordance with the disclosed
principles. In
this embodiment, the an active positioning system would still include a
powered system
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CA 3044444 2019-05-28
on or within the cable carriers 11 that would be capable of turning the
carrier(s) 11 within
the wellbore 1 to the desired orientation. Actuators, such as electric or
hydraulic motors,
electrical solenoids, hydraulic pistons, and/or other powered devices would
again be used
to apply a rotational force to the carrier 11 by applying wheels, pads, slips,
or other types
of gripping devices either against the casing 3 or the wellbore wall 1. In the
embodiment,
the drive wheel or gear 26 powered by the actuator(s) within the logics module
25 has its
contact surface with the interior of the wellbore wall 2. As the actuator
turns the drive
wheel 26, the wheel 26 actively adjusts the rotational position of the carrier
11 with respect
to the casing 3, but in these embodiments by driving the wheel 26 against the
wellbore
wall 2. The weight and length of the casing 3 would be sufficient to keep the
position of
the casing 3 steady while the carrier 11 rotated around the exterior of the
casing 3. As
before, as the rotational position is adjusted, in either direction, the
logics module 25 again
determines the positioning between the two and can provide that information to
a user via
a control terminal, application, or other means of display to the user. The
user may then
not only determine the precise position of the cable 5 or other parameter
detecting device,
but can adjust that location in any direction as needed. Also as before, this
embodiment
of the powered system may again include centralizing devices 24 or other sized
stabilizing
devices for assisting with positioning of the carrier 11 and casing 3 within
the wellbore 1.
Preferred Embodiment Operational View of Cable Feeder Assembly
100731 In another preferred embodiment shown in Figure 10, an exemplary cable
feeder
assembly 10 deploys the flexible polymer cable 5 to the drilling rig 19 by an
articulating
hydraulic arm 16 that may be mounted on a flatbed trailer 18 along with a
cable spool 17.
The cable 5 feeds from the spool 17 along the articulating arm 16 to the
drilling rig 19.
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CA 3044444 2019-05-28
[0074] Figure 11 provides an enlarged operational view of the articulating
hydraulic arm
16 and the cable 5 feeding from the spool 17 along the articulating arm 16 to
the drilling
rig 19.
[0075] Figure 12 provides another enlarged operational view of the
articulating hydraulic
arm 16 attached to the drilling rig 19. The flexible polymer cable 5 feeds
along the
articulating hydraulic arm 16 toward the drilling rig 19.
System Summary
[0076] The present invention system anticipates a wide variety of variations
in the basic
theme of extracting gas utilizing wellbore casings, but can be generalized as
a wellbore
isolation plug system comprising:
(a) A flexible polymer cable with embedded wires,
(b) A system for handling said flexible polymer cable,
(c) A means to hold the flexible polymer cable along a casing wall surface
to
allow distributed sensing of at least one wellbore parameter; and
(d) A cable feeder assembly that feeds the flexible polymer cable from the
spool to the drilling rig and into the bore hole;
Wherein
The system is configured to feed the flexible polymer cable into a wellbore;
and
The system is configured to allow rotation of the wellbore casing or tubing
within
the longitudinal axis of cable carriers; and
The anchor subassembly and the intermediate cable carriers are configured to
support the weight of the flexible polymer cable in the downhole
environment.
[0077] This general system summary may be augmented by the various elements
described herein to produce a wide variety of invention embodiments consistent
with this
overall design description.
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Method Summary
[0078] The present invention method anticipates a wide variety of variations
in the basic
theme of implementation, but can be generalized as an instrumented wellbore
cable and
sensor system comprising:
a) A flexible polymer cable with embedded wires,
b) A system for handling and feeding said flexible polymer cable into a
wellbore,
c) A means to hold the flexible polymer cable along a casing wall surface to
allow
sensing of at least one wellbore parameter;
Wherein the method comprises the steps of:
(1) installing wellbore casing;
(2) deploying flexible polymer cable along with the anchor subassembly and
intermediate cable carriers to a desired wellbore location in the wellbore
casing;
(3) activating the sensor or communication cables embedded in flexible
polymer cable at the desired wellbore location;
(4) Gathering desired geophysical data.
[0079] This general method summary may be augmented by the various elements
described herein to produce a wide variety of invention embodiments consistent
with this
overall design description.
System/Method Variations
[0080] The present invention anticipates a wide variety of variations in the
basic theme of
oil and gas extraction. The examples presented previously do not represent the
entire scope
of possible usages. They are meant to cite a few of the almost limitless
possibilities.
[0081] This basic system and method may be augmented with a variety of
ancillary
embodiments, including but not limited to:
CA 3044444 2019-05-28
= An embodiment wherein the system is further configured to be deployed
from a
cable spool using a hydraulic, articulating arm mounted on a flat-bed trailer
adjacent to a drilling rig.
= An embodiment wherein the system is further configured to allow a
hydraulic
articulating arm to attach to a drilling rig and guide a flexible polymer
cable to the
drilling rig.
= An embodiment wherein the system is further configured to allow the
annulus
space between the casing and the wellbore to be cemented after deploying the
instrumented sensor cable system to the desired wellbore location.
= An embodiment wherein the formed metal jacket completely encapsulates the
ruggedized sensor cable element.
= An embodiment wherein the intermediate cable carriers are fabricated from
material that is selected from a group consisting of: aluminum, iron, steel,
titanium,
tungsten, and carbide.
= An embodiment wherein the flexible polymer cable material is selected
from a
group consisting of: a non-metal, a low-friction polymer, an erosion resistant
polymer, and a metal or ceramic sheath.
= An embodiment wherein the shape of the ruggedized flexible polymer cable
shape
is selected from a group consisting of: a flattened sphere, a crescent, an
ellipse, a
flattened rectangle and a flat cable.
= An embodiment wherein the shape of the flexible polymer cable is a
flattened
ellipse or rectangle.
[0082] One skilled in the art will recognize that other embodiments are
possible based on
combinations of elements taught within the above invention description.
CONCLUSION
[0083] An instrumented wellbore cable and sensor deployment system and method
for
rapid deployment of fiber optic distributed sensing cables, conventional
electronic cables,
or hydraulic control lines in the annulus of a wellbore without the need to
clamp cables to
the casing or tubing string for support.
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