CA2195896A1 - Downhole production well instrumentation - Google Patents

Abstract

A downhole production instrumentation comprising a modular tool used in the acquisition and control of information, and actuation of electromechanical devices in a production well is presented. The tool is suitable for both permanent and retrievable applications for measurement of production fluid and geological formation parameters. Multi well/multizone monitoring and control can also be provided with the instrumentation of the present invention. A data acquisition surface unit located at the surface provides production well monitoring and control.
The tool comprises a plurality of interchangeable instrumentation modules and a control module. Interface between the downhole control module and the data acquisition surface unit is provided over a single conductor cable, which supports both communication and power over a single conductor as is well known in the art.
This cable may be connected to a plurality of tools in a corresponding plurality of zones by a parallel connection to the single conductor. Each tool will preferably have a unique address for communication with the data acquisition surface unit.
Each instrumentation module interfaces over a tool bus with the control module. It is an important feature of the present invention that a standard interface and connection be developed, whereby a tool may be configured (or reconfigured) using a control module any one or a number of interchangeable instrumentation modules.The downhole modules include instrumentation (sensors), such as, pressure, temperature and flow gauges, gamma ray and pulse neutron detectors, or any other suitable devices for measuring production fluid, geological parameters and the like.

Description

-ROr1 EHI Dq~ 3EPT 71~ 1--g ;31Z~3 l~g~ ~ ' #6'~ 2--

2 1 958~6 B~cl.~.uu~d nf th~ Invent~on ~i~s inv~nt~on relate~ ~enerally to dow~ole produc~on weU ~n~trumentation. ~Ore pa~ticulally, thi~ invention relates to downhole production wel~ instrumenta~on compri~g ~ plurality of in~r~hange~blQ n~ e~
S Thc concrol of oil zlld ga~ pro~luction well~ c- n~'ir~te~ an on-~oing concern of tlLe pet;roleum mdu~try due, in part, to the enormous mone~ry expen~e involved a~ ~ell as the ~sk~ as~ociated w~th environm~nt~l ~nd safety is~ue~. Production well control has beco~e particularl~ important ~nd more complex in view o~ t~e indus~ry wide recognition that wc.lls having ~nultiple branche~ (i.e., multi~at~ wells~ wi~l be ~crea~gly import~nt and 1~ comn~onrlsce. Such multilater~l u~e~l~ ~ncl~de discre~e production ~ones which l~roduce fluid in either connmon or di~rete produclion tubing. Ln either ca~e, there ~ a nced for contro~ing zone production, isolatin~ speci~c 20ne~ and otherwi.ee monitor~ng each ~onc ~
p~rticula~ welL
Before describin~ the cu~r.ent ~tate-of the-art re!ative to such production well control ~ st0-n~ and m e~hod~. a brief dcscriptio~ wi~ be made of th~ production sy~tems. per ~e.
Ono type of producti~on system utilizec ~ ic~l ~ubmersil)le pumps OESP) for pumpin~
fluid~ from dow~hole In a~ tinn, there are twn oth~r gener~ )eg Oi pro~ ctlnnc sy~tems for oil alld gas wel]~, ~amel~ plunger lift and ~as ~ift. P~nger l~ft prodllc~i~ n iy8tem8 include the u~ of a ~m~l cylin~r-r~l plun~er ~hich travel5 through tubing ex~ending frcm a location ~dj~cent the produc~ng fnrmation down in the borehole to 8-lrface e~qUipD ent loc~ted at the operl end of the borehole. In general, ~uid~ which colle~t in the borehole and inhibit the ~low of fluid~ out of the f~rm ~tiO~l ~nd into the wellbore, are eollected in the tubing Per~odically, the e~d of l;he tub~ng i~ opened ~t the ~urf~ce ~d the accum~3ted reser~oir prc~ure is 3u~'1;cieut GO force the plunger up ~e tul~ing The l~lunger carries with ~5 it t~ the ~u~face a lo~d o~ ~ccumul~ted fluidfi which are eiected out the top of the well lhereby allowin~ ,~,a5 to nOw- more l~ecly ~om the formahon into the wellbas~ and be delivered to a dis~ribution sy~te~ ~t the surface. Af~er the flow of ~as has a~am bec~r~e ted due to the f~ther accumul~tion of fluids dowllhole, a vah~e in 1he tub~ng ~.1; the ~urf~ce of the w ell is c~o~d ~o that the plunger then all~ ba~:k down the tubing and ~s ready =I~Or1 E~I I ~q----`J-- ,EPT 7;, 1 ,g ;3~ =197 . 1;~1 - 2' ~ -1 ~;~;3 c ' . a~3 ~7 nother load of llu~d6 to the surface ~lpon the renpening of the v~l~re A ga~ lift produc~on ~;tem ~nclude~ a valve ~stem 1'or control~ing the ~njecti~n of p~es~ur~.zed ~as f~om a source cxternal to the well, such ab another ~as uell or a compre~or, into the borehole. Th~ increa~ed pr~ II the injected ga~ forccs accumulated S format~on nuid~ up a central tubi~e Q~n~ing alon~ the borehole to rem~ve the ~lu~ds and re~ore the free ~ou~ of gas and/or oil i~rom the forma~on ~nto the well In uel~s where li~uid fall back ie a problern d~g ga8 lift, pl-ln~er lift may be combined with ga~ Jift to ~mp~ove e~;ciency.
o~h pl~m~er li~t and ga~ lilt production ~y~tems, the~e i~ a requ~ement ~o~ the po~io~ic operation of a r~otor valve at t~e ~rface of ~he wellhe~d to control either the flou of fluid~ ~om the well or the flow of injection ~16 into the well to a88i~t in the production of gas all~ liqu~d~ li;om the well. T~ese motor va~ve~ ale conven~donally contro]led by timing m~rh~n ig~ and are prog~ammed in accord~ncc with principle3 of reser~ oir eng~n~ering which determ~lle the le~th of time that ~ well ~hould ~e eit~ hut in" and re~l,ncted ~om the flowing of ga~ o:~ liquid~ to the surf~ce arld the ti~no the we~l ~hould be "opcned~ to frecly produce. GeneraIly. the criteQa u~ed for operation of thc motor valv~ is 6t~ctly one of the elap~c of a pre~e~ect~d time ~criod. ~n most ca~es, measured well parameter~, su~h as prc~8ure. ~empc~ature, etc, a~e used only to override the ti~i~g cycle in gpecial cond:ilicn8.
~t will be ~ppreciated that rel~t*e~y ~mplel timed ~nter.~ittent operation of mot.or t valve6 and the like is of ;en ~ot adequate t;o control either outflow f~om the well or ga~
injection to the we~ ~o as to optim~ze ~vell produetion. As a con~equence, ~ophi~ticated computerl7ed controllers have been posinoned ~t the ~ ace of product;on ~ elLs ~r control of downhole de~ices ~uch as the mot~r ~alve~.
~n flddition. such ¢omputer~.ed eontroll~r~ have been tl6ed to control other do~nhole device6 such as hydro-mech~ni~l s~fety valves. Th~e typic~lly microproc~or basedcontroller~ are al~o u6ed for zone contro~ within a w~ll and, f~r exampIe, can be used lo ~ctuate ~lidin~ sleeve~ or packc~s by the ~ans~ biu5~ o~ a ~urface cornma~d to d~wnh~lc nlicroproces~or controll~rs and/or electr~meçh~nir~l control device~.

-. -g ~e ~ ' 3'3~ 2 ~ 6~13 P. 39 '2-' =ROM : E~H r PRT--~`~T 3EpT , ~3 ~, 'rypica]ly, production pern~nent gauge~ are placed ~n a wellbore lo mon~t~r parameters related to the production o~ hy~rocarbon~ dur~n~ the life of the welL The~e ~auge~ are connected el~ r;rAlly to the ~face v~a a ca1~ie norms~lr mounted to the out~idQ
of the pro~uction ~ubing. Power and comml~n;c~ n~ are ~ccomplished over t;he c~ble.
Genera~ly, one ~r~ ;6 u6ed fo:e each ~auge placed downhole. ~e ~rface ~stem u~ed to gather ~nd pr~ce6s the data requirc6 ~ ~ndividual data ac~ ition sg tem for eac}~ gauge placed downhole Thi~ e number of data a~uibilion ~ystem~ increa6e~ the complentyand C08t of the ~ysten~, a~ well as decrea6e~ reliability of the ~urf~ce hardware. I~he use of multiple downhole wireg increa~ the C08t of d~ploying a 8y8tem, ~nd li~it~ the nu nber of 0 ~auges that c~n be placed in the well.
Elettric~lly ~ubmersible pump~ u6e pressure ~nd ~emperatu:re reading~ xece,ved at the surface from downhole cen~or~ to change the ~peed of the pump ~n ~e bo~ehole. As an ~Iternative to downhole 6ell801~, wire line product~on log~ tool9 arc al~o used ~o provide downhole data on pre~ure, temper~ e, f~ow, gamma ray and pulEe neutron usi~g a wire line surfacc unit ThL3 data i~ then usedfor control of the prod-~c~i~n well.
There ~re nnmexou~ pnor ~t p;~tents rel~ted to the control of oil a~d gas produc~ion well~. In general. th~se prior patent~ relate to (1) ~urface cont~ol ~y~lems using a surface n~icroproee~or ~nd ~2) downhole ~ontro1 8~9tem3 which ~re initiated by su~dce cont~ol 6i~n~
The ~urface control ~stem paten~ gencrally aisclo~e compllter; ~ed ~stem~ fo~
mor-itnnn~ ~nd controlling a ga~oil production ~veU where~ the control electron~cs ~s 10cated at the ~urface ~nd comml~ni~qte~ with ~en3orc and elcctromeeh~nic~l deYic~s ne~r the surface. An example af a system of t~i~ type i~ de~cribed in U.S. Patent 4,633,g61~'~54) to DL~con et al. ~he s~tem de~cribed m the 'g54 p~tent ~rlrlllrlP~ a full~ progrsm rn~
~5 mic~pro~e~ contro~ler which manitor6 dawl~hole p~ramete~ such a~. ple~6ure and nOvt and controls the operation of ~a~. injection ta the we~l, olltf~w of fluid~. from the well or ~.hutting ~n of the well to ~naxim~ze output of the ~ve11. .~other e~ mr~le of a con~ol s~.tem of this typc i~ de~cribed ~n U.S Paten~ 5,lq.2,904 ~904) to Lamp. The ~904 pacent &i~clo~.e~ a sy~.tem similar to the 9~4 patent and ~n addition alfo describes a feat~re wherei.7~ the =ROt1 : ~HI P~ EPT 71~ ~3g 81Z4~ 139, . e. - ~2 :--:--5 #6C0 F~ '2 ~

controller i~cl\-des serial ~nd parallel comnl~ni~ on p~rts through which all ~omm-~ nir~t;on~ to and f~orn the controll~r pa89. Hand held de-rice6 or portable comp~ters eapable of scri~l comm~lni~ ati~ may access t~c controller. A telPr~on~ modem or telemetry linl~ to a ce~ltral host computer may alfio be u~ed to permit several controllers to be ~ce~ed remol;el~.
U S. Patent 4,7S7,31~ C31~) to Aubin et al de6cribes an ~pparatus ~or con~rolling and rrlonit~lring a well head ~ubmerged ~ ter. Thi~ ~y~tem inrlu~e~ a plur~l;t~ of sensors, plurality of electromech~nir~l valve~ and ~n elec~onic corltrol system ~h~ch commun~cale~
with the sensors and val~7es. The electronic control ~tem is po~itioned i~l a ~ater ~ght ' O ~nclosure and the water tight ~nrlo~ submer~cd underw~ter. The el~ronic6 located in the ~bnlerged enclo~ure control and operale the electrome-~h~nic~ val~es based on input ~orrl the sensors. In particul~r, the electronics ~n thc enclo6u~e u~ the deci~ion maki~g ~bilitie6 of the mic~opro~e~or to monitor the ca~le inte8rity feom the surface ~o the well head to autom~t;~lly open or c~o~e the val ~ hould a break in the line occu~
l 5 The do~nhole control ~y~tem patent~ geoerally di~close downhcle m~croproce6~0r control~erg, electrom~rh~r ir~l control dev~ce~ ~nd ~ensor~. FYS~ include ~J S Pat~ent No. ~,718,011~011~ to Pall~r~or~; U.S. Patent No. 5,273,113 C113) to Sc~ultz, and U.S.
Pa~ent Na. 3~969,767 ~76n ~ ~mit~er et aL
Th~ p~tent describe~ a ~y6tem for rcmotely controlling a downhole tool in a welL A pluralit;y of sub~tantiallg idcntical command si~nal~ are tr~n~mil~ed into the well ~ach of the commarld s~gna].s i~ receivQd at the do~vnhole tool by a control~e.r hav~ng ~nformat~on st~red there~n identifyin~ an oper~tivo comTn~nd ~ign~l s~gnal:ure asso~ia~d ~rith that tooL
The '011 patent de~nbe~ a do. wnhole m~cropl ocess~r controller di~po~ed ~n a ~ve]l ]ogging sonde Yvhich rece~e~ a~d ~tore~ one or morè pr~selecte-1 tables o~ ~enes of ~o~ g tool comm~nd~ down load.ed liom a ~urface c~n~pu~,er throL~gh a hg~ng cable telemetry link A~ ~uch command~ in a gi~ cn tab~e ar~ c~lled up by the controUer i~om mcmory inrespon~e to a corregpond~g sequence cornmal~d ~om the 6urface computer co~Te~pnn~ g with the de~ircd t~ble -Ror~1 : EHr ~q~ OEFT , ;3 .~3g ~;~z"~ 139. i~ ': ~5 ~;53 P. 11 2~.
21 958~6 The '767 patent de~cribe~ ~n apparatu~ for communicating, ln digital form, ~nformation from a plurality of anaLog source~ located ~n a borehol~ to a locatio~ on the Eurf~ce ~ m~lhrlP~er i~ provided ~ith a plurality of i~put;~ for connPc~ ng the ~nalog ~ignal ou~l~t of the d~ta ~ rce~ to an ~n~log to ~igital converter in re6pon~e to ~ ~equence control ci~cuit 1~ne digital dat~ signals a~d their ~ddr~es a~e applied to modulate or vary the power fact~or of power on a power cable mourlted i~ the borehole. Receiver means i~
proYided at the su~face location for ~e~ g thQ digital data and addre~s ~ als for oll th~ ~urface While lt ~ well recogn;fad th~t petro~um produc~ion n~ell3 will have mcrea~ecl ~o produ~tion effiei~ncie~ 3nd lower operat~n6 co~ts if 6urface con~puter based controllers ~nd downhole microp~ essor contloIler (actuatod by externa~ or s~ ce ~ of thc type di6cus~ed h~reinabo~e a~e used! the pre8ently imple~ented ~on~rol system6 nevertheless suffer rrom drawbaclc~ and dis~d~ant~ges.
In mlllhl~JPr~l weIls where m-lltiple zone~ are eontrolled by a single ~urfaee co~trol 6~tem, an inherent r~k ig that if the surface contro]. ~y~tem fail~ or other~se ~hut~ down, t~en all of the dow~ole toolg and other p~oduction equiplnerlt in each sep~rate ~onc will mil~ rly ~hut down l~ading to a Large 106~ ~n produ~tion ~nd, o~ cour~e, a lo~ In revenue.
Still another ~i~ificfl~t dLdw~a~k of pre~ent produ~tion well cont~ol sy3tems invo}ves the extremely high C06t associated with ~mplem~.nt~n~ ch~nge~ ~ well contml and related wo~k over operation6. Pre~en t~y, if a probl¢m i~ dPtec~ed at the well, thc Cu6tomer ~s re4uired to 6e~d Q rig to the ~ ell ~ite at an exl~emely high eo~t ~e.g., o mi~ion dollars for 30 day~ of off~hore wcrk). The well n~u~t then be ~hut in during th~ work ovex cau~irLg ~ e lo~ ~n revenL~e6 ~e.g., 1.5 rnillion doll~rs for a 30 day period). As~ociated w~th the,~e hi~h c06t5 a~e the relatively high ri~ , of ~ erse env~ronm~n~l impact due to spiU~ ~nd other accident~, ~8 well as potential li~bility of per~ann~l at the rig ~ite. Of cour~e, t~e~e r~slcs can lead ~o even filrther co~ts BecaL~e of the h~h ~t~ and ri~ks involved, in general, a customer may delay ~mportant ~nd nece66~r., wor~c over of a ~ir.g]e well until other wells in tll~e area enco-~nter prol~lem~. Th~ dclay may c~u~,e the product~on of the well to deerea~e or be 6hut in until the rig i~ brought in -1~01~1 : EHI PC~ E~T 715 13'3 ~ 3g, . 21~ --'5 #6' ~21 P. 1~,'2--2 1 95,~96 Still other problem9 a~ Dd with pre6cnt production well co~t~ol sy6tem6 ~volve the need for ~ ~reline formation ev~luation to ~en5e chan~e~ in the fnrm a~inn alld fl-lid rnRi1in n Unfortunate.l~, such wi~eline forma~on evaluat~oll iR e.Ytremely expen~ e and time ~n~lming. In ~dd~ n, ~c r~qui~e~ shut-in of the well and doe8 not provide "real time~
inforlnation. 'Ihe need for rcal time infonnabon ~egardin~ t~e f~ tion and nuid eæpecial~ acute in ev~lua~ng un~lP6i-~1e water flow int;o the produchon ~luids.

=RO~ : ~h I F'~IT--U r 3EPT ,~ 1 ~ 4~9 ~-.~ 1 39 . . ~ ~6 :~6'_13 ~ . 1 3,~ 2~
21 9~896 Sunlm~ l;he Tny~n~inn-The a~ve-discu~sed and other rrobleTn~ and deficiencies of ~;he prior ar~ are over~ome or alleviated b~ the downhole production well 6k~ ent~t;~r of t~c pre&ent invention In accordance with the prd~ent inYen~ the downhole prod~ ln mstrumPn~tion cl-m~ e3 a modul~r tool u~ed in th~ a~ition a~ld control of info and açtuatioL of electromech~nic~l deYicee in a produe1ion well. The tool ~6 ~u~table for both p~ nen~ a~nd re~ieva~l~ appl~ s for me~ur0ment of prod~ction fiuid and geo~ogic;~l formahon para~neter~ ~u~ti ~ ell~multi~zorle monitoring and control can also be provided w~th the inst;rum~ntation ol the pre~ent invention A data acquisicion sur~ace un.it located at ~e surface provide6 produ~tion well mnnitoring ~nd con~roL The taol compri~es a pluralit.y of ~nterch~ngeable in~tnunentat~on module~ and a cont~l module. Tnterface betw~en the downhole control n~odule and th0 data acqui~i~;ion ~urface unit i~ providcd over a ~ngle conductor cable, which ~u~pu~ls bot.h comm-~ni~ n and power ovel a sillgle c~nductor a~ IJ lcnown in the art. I~i~ cable may be co~nected t~ a plura ty of tool~ in a correspondin~ plurali~y of ~One~ by a parallel cQnnect;~n to the sin~le conductor. ~ach t~ol will p~eferably ha~e a un~q~le addre~ for co~ r~t;on with the dat~ acqu~b~ition ~urface unit.
Each instrume~tatio~L mo~ule inte;~ace~ over a tool bu~ w~t,h the c~ntro~ mod~le. ~t L8 an ~mp~rtant .~e;~tu~e of the p~QSent irLvention that a ~tandard interf~ce and conrLe~ion be develop~ whereby a w~l m~r be configured (or rccon~ured) u:3ing a control module any one or ~ numb~r oCinterchan~eable in8tru~nt~Ltion modllle~. The downhole ~nodu~sinclude ~trumentation (5ensor~), such as, pre~ure, tempe:rflture and ~o~v gau~e6, gar~ma r~y and ~ul~e neutron dete~tarE, o~ any other suitable deYice3 for mea6ur~n3~ producaon ~uid, geoloe~l para~met~r~ aI!Ld the like. 'rhe modular approach of the present ulYention S s~ilow5 a plur81ity of device~ l;o be coml in~d at any lq~ation in a tool pr~or t,o bei~lg placed II~L
the production bo~ehole.
The above discu6ied ~nd other features and advantages of ~e pre~ent irLven~:ion will be appreciaeed and undersl,ood by those ~killed in the art ~om the following det~iled de6~ripl;ion and dr~w~n~6.

-RO~1 : EHI P~--_'J-- -`EPT ,~ ~9 31Z~ ,3g7 ` 01-2~ ~6 ~6C~21 P, 1~
21 9~896 ~3nef De~c7~oh~m of the Dra~v~nge ~er~rnng now to tlle draw~ngs wherein lik~ elements are n.~ b~ed alike in the &everal FIGURES:
~IG~E 1 is a di~ rnm~tir elevat~on view of a production wellhole employ~ng a modl~lAr tool ~n accordance with the present invenliol};
FIG~ 2 is a diagrammatic ele~at~on view of a multi~o~e production wel~hc~le empl~ying a plur~lity of nlod llAr tool~ ~n a(~ordance ~ith the present irl~lention;
FIGURE 3 i5 a b]ock diagram of the rGodular tool of Fl~;VR~ l;
. o FI&URE ~ i3 a ~hem~tic b~ock rl; .t ~ ~ n~ of the ~ol ~nd tool bus ~n accordance with the present ~nvention;
;F IGURE 5 i5 ~ hematic block dia~ram th~ co~ol modu~ in the tool ot' FIGU:RE l;and URE & i~ a 6chematic block diagrarn of the intelligent partion found in each of ;5 the inter~harlgeah1e in~trument~t~on modules of the tool ~E'I¢UR~ 1.

D~r. ;l~lio~- of the P~qlYrred Embodiment:
Refe~i~ to ~ S 1 and 3, a p~oduct~on well fi.e., complet~d well) 10 enclo~ed by a cas~ng l~ with ~ r~g 14 at the Eurface u generally 3hown, Euch being well known :in the art. Adownholc instrumentalion tool m accordance with the present in~cntion ~fi genelally ~hown at lG; Tool 16 i5 u3ed in the açqui~i~ion and contr.ol of inform~tion, and actu~tion of electrome-~h~nir~l device8 in ~ production ~ell. It i~ withiu th~ ~eope of the present invention that tool 16 ~ ~uit~ble for both permanent (ie., the tool ~em~iIls dowlth~le throu~hout production operation~) and retrievabl~ applir~ ;on~ {~r measurement of pro~uct;~n fluid ~nd e. ~ ormation p~r~meters. Multi wellt~ ti~one n~oni.t~ring and control (FIG~E Z) can also be provided with thc ~n~trumen1iation of the present in~ ent;on~
A data acqui~ition surf~ce unit 181tx~ted at the surfac~ ~or pl~tform~ pr~vides production well monitor~g arld control, such being fully de~c~ibQd ~n U.S. Patent Appli~atian No.
08~385,9~2 entitled l)O~T~OLE PRO~UCTlON ~rELL (~ONTROL S~STE~ ANTr) =F~0~1 : El~ I Pq~ T --EPT 713 4~9 ~3 . 3~ ~ 2 ; ': --`6 ~:~;'3 P . 15,' 2 ,-~ 1 9~896 ~ETHOD, filed Fcbruary 9, l~gS, by Paulo Tubel et aL which is cxpre6sly incorporated herein by reference in it~ entirety.
In~trumentation tool 16 compri~e~ a plurnlit~ af interchangeable m~dules 20A h and a control module ~2. In~er~ce betwcen tile d~wnhal~ control modLIle 29 and data acq~ tion ~ur~ce unit 18 i~ provided over a 6~ngIe conductor cabLe 35!. Cable 32 suppart6 both conlm~ n;r~h~n and power over a ~ingle conduc~r as ~s well hlowll in ~e ~rt.
F~rther, w~h referencc beiD~ m~de t;o FIC~URE 2, c~le 32 i~ connected to a plural~t~r of tool~ in a correeponding plurality of ~one~ by a paraL~I connec1~ n to th e s~gle condu~.tor.
E~ ~l will prefer~hly have a uniclue addre~ for comm~lnic~t;on with d;~ ~cqu~iho~
~urface unit 18.
Referring also to ~fGl~l~E 4, each mod-lle 20a-h ~nter~aces over a tool ~U5 2~ (ie., a multi-con~uc~or cable~ Wil:h control module 22. Each modul0 20a~h and 22 i~ preferably ennno~ d ~I~ par~lel ~o bu3 24, althou~h a dai~y l~h;~in ~ tion could be ~mployed.
M~ 0a-h Euld 22 are attache~ to bu~ ~4 b~ l~r~?dcfinell. ~nnectvr pin~ at the top a~ or ~5 bottom of Qaeh of the mo~ule.~. It i~ a~ importaIIt featllre of the yre~n l. inven~a~ that a ~tanda~d interface ~nd cnllln~ction be deve~oped, whereby a t~ol may ~o cc,l! G~ ed ~r reco~ red) u~ a eon~.rc~l rnodllle a~y one or a numbe~ of interchangc:lblE
~n~trumentatiOn module~.
The tool bus 24 eo.~ a di~tal data tr;3n~fer bu6 ~aving one or more sign;~l e~) 36; a low power Yo~age line ~8; a high power vol~age line 40; a:~d a ground ~or return) ]i~e 42. :~igi~l. data tran~fer bu~ 36 ha~ one or more s~al li~e6 (a d~ffer~tial signal) utiliz;in~ a s~nda~d trarlsmis~ion method for all downhole mo(1ll1Gc, e.g., RS 232, RS-48a, or ~lil Spec 155.~. More import~ntly, a standard com~l]niear.ion ~yctem i~ u~ed whi~h Y i~l allow colnp~tibilit~-~nter( h~ny~bility o the downhole modnl~ transfer ~ dat~ from a module ~ h to the control module 22 ean be i~itiated by the control module re~e6ti~g dat~ or can be programm¢d i~to module ~Oa-h to tr~ m~t datfl a~ spe~ific 1ime in terva~.
Cont;rol mod~e ~ ~ deten~;neg b~6 6tatu~, ic., if the b~s i~ bein~ u~ed, an~ will take t~vRr the l~ux if it ~l~t~mirlc:; that the data tran6fer lin~ are llol: hoin~ used =R~ ~HI Pq~ ~PT , 13 ~39 '~ 7 13~ 2--~ -- #~;~1 F'. 1~;, 2--~1 95896 Referring 1;~ ~'lCURE ~, control module ~2 comprises a control cinuit 4~. A low voltage pow~ c~rcu~t 46 is provided for delivenne low voltage power o~-er the ~ol bu~ ~e 38 and return line ~ to mf~ Oa h. A hi~h voltage power ci~cuit 4~ rovided f~r deliverin~ h vol~age pow~r ov~r ~,he tool bu~ ~e ~0 and re¢u~ e 4~ ~o module~ 2~a-h s for opcration of bigh powcr device~. High voltage p~wer circuit 4~ ~& controlled by control c~rcuit 44, ~hereby cnn ccl c~rcuit 44 ~rill enable th~ high volta~e POW~r In re~p~n~e to a comm~nd ~ent to a p~rt~ular module 20a-h t~ start t~c o~ of the ;high po~ver de~7ice ~ d m the particular mod~lle- The ~i~h voltag~ po~er ~fi roquired for operatiorl of cert~in downhole high power elcctro~echan}cal devices, e g.. explo6i~es, or any high vo~tage~ h 1~ c ur~ent sys~em. l'he use of Bl~pu:rnte high and low voltag~ power lines helps to pre~enl, corrullLicln af the l~v voltag~ power ]in~, a~ elec~ l no~e typic~lly ~reated b~ the oper~tion an elec~romesh~nir~l device ~uch a~ a motor will prim,~nlv only }~e pTes~nt o~l the high voltage powcr liIle Cuntrol m~dule 22 fureher in~:ludes ~ data transfer c~rc~t SO for tran~mitting to ~nd lS receiv~ data from the dowllholc moduIes. I:)ata ~;ransfer c~rcnit 50 communiratq~ o~er the ~igital interfa~e hll~ line 36 an~ L6 con~rolled br c~mtral c~rcuit 44. A c~rnml~ n ic4~tion circ~it ~s provided fo~ telemelry ~f d~a between the ~ e ~nd downl~ole and v~ ersa. A
~u~ee/downl~n]l, interface C~CIllt ~4 iB pro rifl~d t4 re~ll~te the pow~r in~r~C~, Control eirclut 44 aLso decodes anll form~t~ the data to ~terfac~: with the data acqui~ition ~llr~c~
unlt for proce~ in~ thc data The data ac~uisition ~u:rface unit may in~]ude a printerJp~ol;ter fnr ~ener~ting a pal~r recor-l oFever~ ccurnn~ in the well, ~ ~., prod~c~ioniformahon eYaluatiun ~ng~.
T~lemetry f~r e ~chA . ~ ing in fi~ on iB prefera~ly ~igitaL In accv ~nce ~ith which, A unique ~ddress ~ I;ran~mit~ l from the data acqui~itioil surr~c~ un~t to the downhole tool ~or tools, ~ UEE 2~, fDllowed by dat~ o~ ~ commalld t~ansn~i~ion ~e do~vnhole modules ~ia the control module re~en~e the infr~rmation and det~rmine if the addrcx6 it ~:a~ programmed wi~ m~t~he~ the addre~ sent fro~n the ~nrface ~ie., all module~ :in that tookece~ve l;he 6ame tr~n~nitted infior~1;on on ~he bu3). Only the t~ol ¢h at ha~ the proper addreRfi ~ill re~pond to dlQ cnm ln ~ 1 from ~e ~- rface, Therea~ r th e =F'0~1 : EH I P~ 3EPT 713 _---~ 31Z--3 139 ~ 7 ' ~ ~ ~ . 1-- 7, 21 q58'~6 corredpondin~ ~ole mo~ule ~ the ~electcd tool WilI activate a~ tructed, c.g., close a valve, or will traI~fimll; coll~ted d~ta. ~n aecordance with ~e cnmm~-ld l'he d~t~
aca~ition ~ur~ce unit: w~ll con~nuously p~le the d~wnholc tool (~r tool3~ for inform~t~on nnd 3tatu~.
S Refe~ng to FIGURE 6, each m~lulc ~Oa-h ~ncludes a micro concroI~er ~6, non vol~tile memory 5~, a communir~io~l* bu~ int~ ce ci:~u~t ~O, an allalog to di~ital conv~ter 6~, an anal~ ~ell.~r enn-liholler c~cu~t G~ ~nd a pawer (xmditiorler circ~t ~.
Mi~ro controller ~6 p~eferably inr~ e~ in lhe ~ame ~Uicon waf~r, tlle central pr~es~ing ur~t, non volatiIe ~omo~, random ~cce~s memory, and ~1 ral t~ime cloclc Intqrnal bDlers ;0 per~orm the d~ra proce~4~ng, provide th~ timi~g f~r the data acq~ n, and pack the data for tr~nsfer to control m~dule ~2. ~icro controller ~6 could be replat:e~l with a ropr~essor. Mi~ro con~rQll-~- 56 aL~a ~eeolles comnn~td~ received from conl;rol r~odule ~. Non velatiIe m¢morv 58 co~tain~ codeg u~ed by micro con~lle~ 58 to perfnr~n preprogr~med fun~tioll6. Bu~ interface c~rcuit ~0 con~ert~ the voltage~ ~om the lS commullic;l~ions bus t~ the digital le~els comp;~tible to ~icro colltroller 6~. ~3us inl~rrr1~e c~cuit U) al~n illLOrraces w~th bus 24, ~naIog to d~ ..ql eunverter 62 ~ ;l; dS the data ~Lr~
the ~en~r~, e ~ . pre~sure ~ensor, t~ Lur~ ~en~r, flow ~ensa~, ect. Ana~ en6~r con~3it~ er circuit G4 pro~ the signal to drive the ~an~r, and I~rocc~ the raw data for evmpatibility ~ith allalog tO digital convErter ff2. PoweI~ conditioner circuit 6fi ~nrlihr~n~
l,he power i~ro~ colltrol module 22 to generate the volta6,~es requ;red to operal;e the sen~or~, and elecl~rnnic.~ wirhin the module.
By w~y ol excmlple~ the tool compn~ eorltfo~ le ~2l pr~sule ~odul~ ~Oa, ten:lperature modnle 20b, fluid 1a~ modul~ 20c, wa~er cu~ ~enEar module ~Qd, RC9]iTlg removal module ~Oe, resi~tivity modulf~ , acou~tic module ~0~ and electrome~hanical module ~ ., a fluid Llow ~on~l sub) 20h Gontrol mo~lule 2~ prn~ le~, the foLowin~ filnct;~tn~;
~l) communi~h~.nR bct~een the g~r~ace and downhole;
~3 eontrol of downl~olc modul~.

=R01`1 : ~HI PR '~ 81EPT 713 1139 ~ _ ~3~, 21-2~ ~ #6'C~ P. 18 2~
2 1 958~6 ranEifer among mr~ e~;
(4) power converE~n to provide the r~quired voltage and current to the mDdule~; ~nd (5) ~ata p~ng for tran~fer to the ~urface.
C~ntrol mc~dule 2~ generates t~e ~ tior~ d to provide power and communicat~on~
to the modulee that cu~p-i~c the do~nhole tool 16. Pre~sure module 20~ comprise~ a pre~6ure ~en6or for 6ensin the annulu~ or tuh~ng pr~g~ure th~l; is u~ed t~ the determine the optimuJn flwd prod~ctinn fr~m a particular ~6010gical 2cne to the welibore. Temperature }Ilodu~e ~Ob co~pr~es a temper~tu~e sen~or where~n the s~n~ed ten~per~ture ~ ~ed to correct the pressur~ movementg and to determine if an ~ lec~l su~mersible pump ~:S~
malfunctioning ~Iu;.d ~low modllle 20c con~pr~e~ a flll-d flow 6ensor with the flo~
nea~urement indicating of the amount of ~luid that is fl~llving th~ou~h a particul~r zone ~
~e welL Wato~ cut sen30r module 2W ~c~ 6 5~ ~vater cut ~ensor to detarmir~ the amount of wal~er, oil, ga6 ~nd solid6 th~t ~re flo~g b~ the 6ensor. It i~ well ~own în the art that so~ca~led '~ca~ing' ~ a major problem in a producing well ~e specifica~ly, thc ~c~u~ul~tion of such thmgfi as par~ffin can reduce tbe flow ~rea i~ the tub~ug red~cing the a~nour.t of h~LocArboaæ that c~n be recovered fi om the well. Scalin~ remo.~al module 20e i~
p~ovidéd to remove these a~cuolulations iJl the production tubing. ~ t~ornecharlic~ql sub 20h i~ used to actuat.e a device gu~h as a ~liding ~ re, for 1iow control from a zone in the well, and a p~cker used fo~ the isoI~ of dii~erent ~olle6 in the bor~ole. The rc8i~ti~ty and acous1~c nlodules 20f, 20g monitor the water n~ovo~ent in the proclucing for~na~Dns.
du~vnhole m~lllç~ rrlay comp~ses inBtrumentali~n (sensor~), such a9, p~es~ure, tempera~u~re and ~ow gauges, gamm~ ray and pul~e neu~on ~etector~, o~ any other ~u it~ble de~ices for mea r~ng pro~lc~ihn flvid, geolog~r~l par~m~ter6 and the like. The :a~odul~r approach of the pre6ent inventiOn allows a pIurality of de~ce~ to be comb~ned at any 2 s location in a tool 16 pnor to bein~ placed in the pr~d~ctior~ boreholc 10. A mod~e ca~ also b~ configured to eomm-~nicflte with ~en60r6 that are in~talled pern~a~ently downhole, e g a rorma~on evaluatio~ sen~o~. Moreo~cr, the6e 6enYor~ casl, in real t~me, sen~e and evaluate forlnution p~rameter~ ~ncludin~ important in~or~nation re6~rd~ ater m~gratin~ from ren~ zone~. Si~ c~ntl~ thi3 information c~n be obtained pnor t~ the w~ter actuall~

1~

=ROM : F-~11 P~ EP~ ~ 30--3 l~ 2 ~ C ---8 tt~;'3 p. 19,-'2-' 2 1 q58~6 ent~ring tlle produc~ng tubin~ ~nd thorefore cor~ e action (e.g., clo~ing of a ~,-ahre or ~liclin~ ~leel, e) ol~ forrnAr~ treatment can be tal~en p~or to water bein~ produ~ed. I~is real time acqu~ition of form~tion d~ata ~n the production ~ ell cnn~tit~te~ important advance over eurrent wireline techniques in thac the preoent inventiDn ~ far le60 costly and can flnt;C~tP and react to pctential pro~lems befo~e they oecur. In addi~ n the fo-rnation evaluation sen~rs tbemselve~ can be placed much clo~er to the actual ~ormation ~i.e., adjacent the ca~ng or downhole complct.ion t~ then wireline devices which are re~t~cted t~ the interior of the pr~duc~ion tubing.

=RO~I : EHI PRTEN~ ~IEP~ ~13 ~39 81Z 13 ' ~9, . 0 ~ -, ~ ;5: 78 #6--0 P. 20, 2--2 ? 95896 While l~lef~-~ed embodiment~ h~ve been sho~n a~d de~¢nbed, variou~ mo~ eation~
and ~ubs~ ons ma~ be made therew w~h~ut deparl;~ ~om the 8pirlt and s~ope of theinvsntion Accordillgl~, it ~S tO be under~tood th~t the pre6ent ~nvention h~ bee~l de~cribed ~y w~ o~ illuhtra~ion~ and not Limita~on.
What is clai-ned i~:

Claims (25)

1. CLAIM 1.A downhole tool comprising:
   a control module having an uphole interface assembly for communication and power and having a downhole interface assembly for communication and power;
   a plurality of interchangeable instrumentation modules each having a module interface assembly; and a bus interconnecting each of said module interface assemblies of said instrumentation modules with said downhole interface assembly of said control module.
2. CLAIM 2.The tool of claim 1 wherein said bus includes:
   a digital transfer bus;
   a high voltage power line; and a low voltage power line.
3. CLAIM 3.The tool of claim 1 wherein said bus comprises a single conductor for both (1) data or command and (2) power.
4. CLAIM 4.The tool claim 1 wherein:
   said uphole interface assembly comprises, (1) a surface/downhole interface circuit for separating (1) data or command and (2) power signals, and (2) a communications circuit communicating with said surface/downhole interface circuit for transmitting said data or command signals to and receiving said data or command signals from uphole;
   said downhole interface assembly comprises, (1) a data transfer circuit for transmitting module data to and receiving module data or commands from said instrumentation module, (2) a high voltage power circuit power receptive to said power signals from said surface/downhole interface circuit for providing high voltage power, and (3) a low voltage power circuit receptive to said power signals from said surface/downhole interface circuit for providing low voltage power; and said control module further comprises, a control circuit for controlling said uphole and downhole interface assemblies.
5. CLAIM 5.The tool of claim 1 wherein each of said instrumentation modules includes:
   a sensor.
6. CLAIM 6.The tool of claim 1 wherein each of said instrumentation modules includes:
   a sensor;
   an analog to digital converter for converting said analog output signals to digital sensor output signals;
   a memory for storing program signals;
   a controller responsive to said program signals and command signals from said control module to perform functions, said controller for processing said digital sensor output signals; and said module interface assembly comprises, a power interface circuit for conditioning power from said control module to said sensor, and a communication bus interface circuit for providing an interface between said bus and said controller.
7. CLAIM 7.The tool of claim 6 further comprising:
   an analog sensor conditioner circuit for conditioning said analog output signals.
8. CLAIM 8.The tool of claim 5 wherein said sensor comprises a pressure sensor, a temperature sensor, a fluid flow sensor, a water cut sensor, a scaling removal device, a resistivity sensor, an acoustic device or an electromechanical device.
9. CLAIM 9.The tool of claim 5 wherein said sensor comprises a sensor for communicating with devices installed permanently downhole.
10. CLAIM 10.An instrument module comprising:
    a sensor;
    an analog to digital converter analog output signals of said sensor to digital sensor output signals;
    a memory for storing program signals;
    a controller responsive to said program signals and command signals to perform functions, said controller for processing said digital sensor output signals;
    and an interface including, a power interface circuit for conditioning power to said sensor, and a communication interface circuit for providing data communication with said controller.
11. CLAIM 11.The instrument module of claim 10 further comprising:
    an analog sensor conditioner circuit for conditioning said analog output signals.
12. CLAIM 12.The instrument module of claim 10 wherein said sensor comprises a pressure sensor, a temperature sensor, a fluid flow sensor, a water cut sensor, a scaling removal device, a resistivity sensor, an acoustic device or an electromechanical device.
13. CLAIM 13.The tool of claim 10 wherein said sensor comprises a sensor for communicating with devices installed permanently downhole.
14. CLAIM 14.A downhole tool comprising:
    a control module having an uphole interface assembly for communication and power and having a downhole interface assembly for communication and power; and an instrumentation module having a module interface assembly connected to said downhole interface assembly of said control module.
15. CLAIM 15.The tool of claim 14 further comprising:
    a bus interconnecting said module interface assembly of said instrumentation module and said downhole interface assembly of said control module.
16. CLAIM 16.The tool of claim 14 wherein said bus includes:
    a digital transfer bus;
    a high voltage power line; and a low voltage power line.
17. CLAIM 17.The tool of claim 14 wherein said bus comprises a single conductor for both (1) data or command and (2) power.
18. CLAIM 18.The tool of claim 14 wherein:
    said uphole interface assembly comprises, (1) a surface/downhole interface circuit for separating (1) data or command and (2) power signals, and (2) a communications circuit communicating with said surface/downhole interface circuit for transmitting said data or command signals to and receiving said data or command signals from uphole;
    said downhole interface assembly comprises, (1) a data transfer circuit for transmitting module data or commands to and receiving module data or commands from said instrumentation module, (2) a high voltage power circuit power receptive to said power signals from said surface/downhole interface circuit for providing high voltage power, and (3) a low voltage power circuit receptive to said power signals from said surface/downhole interface circuit for providing low voltage power; and said control module further comprises, a control circuit for controlling said uphole and downhole interface assemblies.
19. CLAIM 19.The tool of claim 14 wherein said instrumentation module includes:
    a sensor.
20. CLAIM 20.The tool of claim 15 wherein said instrumentation module further includes:
    a sensor;
    an analog to digital converter for converting analog sensor output signals to digital sensor output signals;
    a memory for storing program signals;
    a controller responsive said program signals and command signals from said control module to perform functions, said controller for processing said digitalsensor output signals; and said module interface assembly comprises, a power interface circuit for conditioning power from said control module to said sensor, and a communication bus interface circuit for providing an interface between said bus and said controller.
21. CLAIM 21.The tool of claim 20 further comprising:
    an analog sensor conditioner circuit for conditioning said analog output signals.
22. CLAIM 22.The tool of claim 19 wherein said sensor comprises a pressure sensor, atemperature sensor, a fluid flow sensor, a water cut sensor, a scaling removal device, a resistivity sensor, an acoustic device or an electromechanical device.
23. CLAIM 23.The tool of claim 19 wherein said sensor comprises a sensor for communicating with devices installed permanently downhole.
24. CLAIM 24.The tool of claim 1 wherein said bus comprises multiple conductors such that variable combinations of such multiple conductors can be used for (1) data or command and (2) power.
25. CLAIM 25.The tool of claim 14 wherein said bus comprises multiple conductors such that variable combinations of such multiple conductors can be used (1) dataor command and (2) power.