A well system includes a wellhead installation arranged at a surface location, a wellbore extending from the wellhead installation and being at least partially lined with casing, a downhole tool arranged within the wellbore and attached to a conveyance extending from the wellhead installation, and a non-contact auto centralizer attached to the conveyance. The non-contact auto centralizer includes a detecting unit operable to detect a deviation of at least one of the conveyance and the downhole tool from a predefined center of the casing, and a re-centering unit including one or more propellers operable to re-center the at least one of the conveyance and the downhole tool toward the predefined center.
Legal claims defining the scope of protection, as filed with the USPTO.
. A well system, comprising:
. The well system of, wherein the conveyance is selected from the group consisting of slickline, wireline, and coiled tubing.
. The well system of, wherein the detecting unit includes one or more gyroscopes operable to detect deviations of the at least one of the conveyance and the downhole tool from the predefined center of the casing.
. The well system of, wherein the one or more gyroscopes determine real-time X and Y coordinates of the at least one of the conveyance and the downhole tool as the downhole tool is conveyed into the wellbore.
. The well system of, wherein the one or more gyroscopes include:
. The well system of, wherein the one or more propellers are selectively operated to individually re-center the at least one of the conveyance and the downhole tool toward the predefined center.
. The well system of, wherein the one or more propellers comprise a plurality of propellers selectively operated simultaneously to cooperatively re-center the at least one of the conveyance and the downhole tool toward the predefined center.
. The well system of, wherein the non-contact auto centralizer further includes a control unit in communication with the detecting unit and the re-centering unit, the control unit being operable to control operation of the non-contact auto centralizer.
. The well system of, wherein the control unit is programmed to activate the one or more propellers to untwist the conveyance within the wellbore.
. The well system of, wherein the control unit is programmed to:
. The well system of, wherein the control unit is programmed to activate the one or more propellers to re-center the at least one of the conveyance and the downhole tool toward the predefined center upon determining that the real-time X and Y coordinates deviate beyond the predetermined deviation threshold.
. The well system of, wherein the non-contact auto centralizer comprises a first non-contact auto centralizer attached to the conveyance at a first location, the well system further comprising a second non-contact auto centralizer attached to the conveyance at a second location axially offset from the first non-contact auto centralizer.
. A method for centralizing a conveyance in a wellbore during a wellbore intervention operation, the method comprising:
. The method of, wherein the detecting unit includes one or more gyroscopes, and wherein detecting the deviation of the at least one of the conveyance and the downhole tool from the predefined center comprises detecting deviations of the at least one of the conveyance and the downhole tool from the predefined center with the one or more gyroscopes.
. The method of, further comprising determining real-time X and Y coordinates of the at least one of the conveyance and the downhole tool with the one or more gyroscopes determine as the downhole tool is conveyed into the wellbore.
. The method of, wherein the non-contact auto centralizer further includes a control unit in communication with the detecting unit and the re-centering unit, the method further comprising controlling operation of the non-contact auto centralizer with the control unit.
. The method of, further comprising activating the one or more propellers with the control unit to untwist the conveyance within the wellbore.
. The method of, wherein the control unit is programmed to:
. The method of claim, wherein the control unit is programmed to activate the one or more propellers to re-center the at least one of the conveyance and the downhole tool toward the predefined center upon determining that the real-time X and Y coordinates deviate beyond the predetermined deviation threshold.
Complete technical specification and implementation details from the patent document.
The present disclosure relates generally to wellbore intervention operations and, more particularly, a system and method for centralizing conveyances and attached downhole tools within a wellbore tubing during intervention operations.
In the oil and gas industry, downhole tools are often deployed downhole on a conveyance to conduct various well intervention operations. At least one challenge in running downhole tools is maintaining the conveyance and the attached downhole tool centered in the wellbore. During downhole descent, for instance, the conveyance and attached downhole tool can each exhibit uncontrolled movement, potentially leading to catastrophic consequences such as severing of the conveyance, which could lead to lodging the downhole tool within the wellbore, and contact with the inner walls of the wellbore (e.g., casing, production tubing, etc.), which leads to scratches and damage to the walls, and damage to the downhole tool.
Conventional solutions to this problem include using centralizers to constantly (or selectively) centralize the downhole tool and conveyance in the wellbore. Some centralizers, for example, employ hydraulic arms that extend to directly contact the inner wall of the wellbore during use. Wells today, however, often feature internal coatings, such as glass reinforced epoxy (GRE), and impose strict requirements against any friction applied to the inner tubing surface. Consequently, passive centralized interventions, even with friction-reduced centralizers like rollers, are deemed unacceptable due to the risk of damaging the tubing's internal coating. Moreover, in scenarios involving heavy crude applications where sticky and dense oil can accumulate on tubing walls, conventional roller-based centralizers become unreliable, impeding successful well interventions.
There is, therefore, a need to provide an innovative slickline centralization solution during well intervention operations that overcomes the limitations of current centralizers.
Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.
According to an embodiment consistent with the present disclosure, a well system is disclosed and includes a wellhead installation arranged at a surface location, a wellbore extending from the wellhead installation and being at least partially lined with casing, a downhole tool arranged within the wellbore and attached to a conveyance extending from the wellhead installation, and a non-contact auto centralizer attached to the conveyance. The non-contact auto centralizer including a detecting unit operable to detect a deviation of at least one of the conveyance and the downhole tool from a predefined center of the casing, and a re-centering unit including one or more propellers operable to re-center the at least one of the conveyance and the downhole tool toward the predefined center.
According to another embodiment consistent with the present disclosure, a method for centralizing a conveyance in a wellbore during a wellbore intervention operation is disclosed and includes the steps of introducing a downhole tool into a wellbore extending from a wellhead installation arranged at a surface location, the downhole tool being attached to the conveyance, and the wellbore being at least partially lined with casing, introducing a non-contact auto centralizer attached to the conveyance simultaneously with the downhole tool, the non-contact auto centralizer including a detecting unit and a re-centering unit including one or more propellers, detecting a deviation of at least one of the conveyance and the downhole tool from a predefined center of the casing with the detecting unit, and operating the one or more propellers and thereby re-centering the at least one of the conveyance and the downhole tool toward the predefined center.
Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims.
Embodiments of the present disclosure will now be described in detail with reference to the accompanying Figures. Like elements in the various figures may be denoted by like reference numerals for consistency. Further, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Additionally, it will be apparent to one of ordinary skill in the art that the scale of the elements presented in the accompanying Figures may vary without departing from the scope of the present disclosure.
Embodiments in accordance with the present disclosure generally relate to a system and method for centralizing conveyances and attached downhole tools within a wellbore tubing during intervention operations. Disclosed is a well system that can include a wellhead installation arranged at a surface location, and a wellbore extends from the wellhead installation and is at least partially lined with casing. A downhole tool may be arranged within the wellbore and attached to a conveyance extending from the wellhead installation. A gyroscopic centralizer tool is also attached to the conveyance and conveyed into the wellbore with the downhole tool. The gyroscopic centralizer tool includes a detecting unit operable to detect a deviation of at least one of the conveyance and the downhole tool from a predefined center of the casing, and a re-centering unit including one or more propellers operable to re-center the at least one of the conveyance and the downhole tool toward the predefined center.
is a schematic view of an example well systemthat may incorporate the principles of the present disclosure. As illustrated, the well system(hereafter “the system”) includes a wellhead installationinstalled at a surface location, such as the Earth's surface, and a wellboreextends from the wellhead installationand penetrates one or more subterranean formations. The wellboremay be cased, open hole, contain tubing, and/or may generally be characterized as a hole in the ground having a variety of shapes and/or geometries as are known to those of skill in the art. In, the wellboreis shown lined with a string of casingthat may be secured in place with cement. While not shown in, in at least one embodiment, a string of production tubing may be extended within the casing.
While the systemis depicted inas a land-based system, the principles described herein are equally applicable to subsea operations that employ floating or sea-based platforms and rigs, without departing from the scope of the disclosure.
The systemmay be configured for downhole well intervention operations. As illustrated, the systemmay include a wellhead, a blowout preventer (BOP)operatively coupled to (e.g., bolted or clamped) the wellhead, and a lubricatormay be operatively coupled to (e.g., bolted or clamped) the BOP. While not shown, additional components may be positioned between the BOPand the wellheador between the BOPand the lubricator, such as a casing head spool, a tubing head spool, etc. Accordingly, the example arrangement of the wellhead, the BOP, and the lubricatorinshould not be considered a limitation of the present disclosure, rather many variations of said arrangement may be included in the system, without departing from the scope of the disclosure.
The BOPmay include a plurality of valves operable to control hydrocarbon production from the subterranean formation(s). The lubricatormay be an elongate, high-pressure pipe or tubular fitted to the top of the BOPand configured to provide a means for introducing downhole tools and assemblies into the wellborevia a conveyance. Examples of the conveyanceinclude, but are not limited to, slickline, wireline, and coiled tubing. The lubricatoris a pressure-controlled device used to initially house downhole tools and assemblies and create a seal between the outside environment and the pressurized environment in the well.
The conveyancemay be coiled (wound) onto a large drumand routed through one or more pulleys or sheavesto be introduced into the lubricatorat a stuffing boxprovided at the top of the lubricator. The stuffing boxcomprises a high-pressure grease-injection section and includes various sealing elements used to seal about the conveyanceas it is fed into and out of the lubricator. An operator rotates the drumto alternately lower (unspool) or raise (spool) the conveyance.
The systemmay also include a downhole toolconfigured to be introduced into the wellbore(e.g., within the casingor production tubing arranged within the casing) to undertake one or more downhole operations. The downhole toolmay comprise a variety of downhole tools, devices, mechanisms, and assemblies capable of completing a variety of downhole operations. In some embodiments, the downhole toolmay comprise a single downhole tool, but could alternatively comprise a tool string or a bottom hole assembly (BHA) comprised of multiple tools and/or devices arranged in series. Examples of the downhole toolinclude, but are not limited to, a fluid sampler, a completion tool, a drilling tool, a stimulation tool, an evaluation tool, a safety tool, an abandonment tool, a packer, a bridge plug, a setting tool, a perforation gun, a casing cutter, a flow control device, a sensing instrument (e.g., a pressure gauge, a temperature gauge, etc.), a data collection device and/or instrument, a measure while drilling (MWD) tool, a logging while drilling (LWD) tool, a drill bit, a reamer, a stimulation tool, a fracturing tool, a production tool, combinations thereof, and the like.
To convey the downhole toolinto the wellbore, the downhole toolis coupled to the conveyanceand placed within the lubricator. The lubricatoris then pressurized to at or above the pressure of the wellbore, and once properly pressurized, one or more of the valves on the BOPis opened to enable the downhole toolto descend into the wellboreon the conveyancevia the BOP. In some embodiments, the downhole toolsimply falls into the wellboreon the conveyanceunder gravitational forces. In other embodiments, however, the downhole toolmay be pumped into the wellboreon the conveyanceunder pressure. In yet other embodiments, such as embodiments where the conveyancecomprises coiled tubing, the downhole toolmay be advanced into the wellborethrough axial loading provided by the coiled tubing.
To remove the downhole toolfrom the wellbore, the conveyanceis retracted and the installation process is reversed.
In at least one embodiment, the downhole toolcomprises or otherwise includes a pressure gauge operable to collect downhole pressure data. To be able to obtain proper (accurate) pressure data, it is preferable to maintain the pressure gauge at the center of the wellboreduring its descent downhole. Keeping the pressure gauge at the center of the wellborealso helps avoid damaging the gauge and the inner walls of the wellbore(e.g., the casing). Moreover, it is similarly preferable to maintain the conveyanceat the center of the wellboreso as to not inadvertently twist or sever the conveyance, or likewise damage the inner wall of the wellbore.
According to embodiments of the present disclosure, the systemmay further include a gyroscopic centralizer tool, referred to herein as a “non-contact auto centralizer”, operable to detect deviation from the center (or centerline) of the wellbore, and further operable to re-centralize the conveyanceand the downhole toolwithin the wellboreas needed. As will be appreciated, this will allow for well intervention without touching the internal walls of the wellboreor casing, and thereby helping to avoid damage to the downhole tool, the conveyance, the inner walls of the wellbore, or any combination thereof.
illustrates an example schematic representation of a section of the wellborelined with the string of casing.also shows an actual pathwayof the conveyance() as it descends within the casingas compared to a desired pathway or centerlineof the wellbore(and casing). Preferably, the conveyancewill descend within the wellborealong or substantially along the centerline. In, however, the conveyanceis conveyed into the wellborewithout a centralizer and, therefore, does not follow the intended/designed path along the centerline.
As mentioned above, the conventional use of downhole conveyances without any centralizer can pose a significant risk of uncontrolled movement, potentially leading to catastrophic consequences such as severing of the conveyance, contact with the tubing walls, which leads to scratching and damaging of the walls, and possible damage to the payload (e.g., the downhole toolof). Further, conventional solutions, such as employing hydraulic arm-based centralizers, face limitations in compatibility with newer generation wells. These wells often feature internal coatings, such as glass reinforced epoxy (GRE), and impose strict requirements against any friction applied to the inner surfaces of the casing. Consequently, passive centralized interventions, even with friction-reduced centralizers like rollers, are deemed unacceptable due to the risk of damaging the tubing's internal coating. Moreover, in scenarios involving heavy crude applications where sticky and dense oil can accumulate on tubing walls, conventional roller-based centralizers become unreliable, impeding successful well interventions. The drawbacks of the conventional systems highlight the pressing need for a system or mechanism for centralizing a conveyance in wellbore tubing.
is an enlarged cross-sectional view of the wellboredepicting an example of the non-contact auto centralizer(hereafter the “auto centralizer”) that may be used in accordance with the principles of the present disclosure. The conveyancetraverses the length of the casingand provides a means for conveying the downhole toolinto the wellbore. In some applications, the inner wall of the casingmay be coated with
GRE and may otherwise be internally coated to enhance durability and prevent corrosion. The auto centralizermay be operable to help centralize the conveyancewithin the wellboreand, more particularly, within the casing(or another tubing within the wellbore). As a result, the auto centralizermay also be used to help centralize the downhole tool(e.g., a “payload”) within the wellborewithout any interaction (i.e., in a contactless manner) with the inner wall of the casing.
As illustrated, the auto centralizermay include a detecting unitoperable to detect a deviation of the conveyancefrom a predefined center of the casing(e.g., the centerlineof the wellbore), which may correspond to an intended/designed path of traversal for the conveyance. In an example, the detecting unitmay include one or more gyroscopesconfigured to detect deviations of the conveyancefrom the center of the casing. The determination of deviation from a predefined center of the casingmay involve a series of steps aimed at evaluating the offset between the actual path (also referred as current/real path) of the conveyanceand its central path (also referred as intended/designated path) within the casing.
In an embodiment, determining deviation of the conveyancemay include real-time monitoring of the current X and Y coordinates of the conveyanceas it traverses the length of the wellbore(e.g., the casingor other tubing arranged within the wellbore). In one or more embodiments, a measurement point may be considered on the conveyancethat is substantially close to the downhole tool. Such a measurement point may be predetermined during measurement of the reference X and Y coordinates so that all future measurements of the “current” or real-time X and Y coordinates correspond to the same measurement point on the conveyance. This continuous monitoring enables the detecting unitto track the real-time movement of the conveyancein relation to the reference coordinates, and provide dynamic feedback on the position of the conveyance(or the measurement point on the conveyance) within the casing.
The wellborecan be deviated from true vertical, slanted, or completely horizontal. The gyroscope(s)may be employed to detect deviations of the conveyancefrom the predefined center of the Wellbore(e.g., the casing) and otherwise configured to detect deviations in the X and Y directions. More specifically, the gyroscope(s) may be operable to measure real-time X and Y coordinates, which are compared against the original wellbore trajectory (e.g., a Deviation Survey or Well Trajectory) of the well. As discussed below, the Well Trajectory is a well-defined document generated when first drilling the well, which includes the X and Y coordinates of the wellboreas the well deepens into the earth. As shown in the enlarged inset graphic, the gyroscopescan include one or more first gyroscopesarranged and configured to detect deviations in the X direction, and one or more second gyroscopesarranged and configured to detect deviations in the Y direction. The detecting unitprovides valuable data by measuring the deviation around a specific axis (e.g., the centerlineof the wellbore), and such deviation information enables the auto centralizerto determine the magnitude of the deviation and take timely course-corrective actions.
In one or more embodiments, the auto centralizermay utilize the center of gravity of the downhole toolas the measurement point for detecting deviation. This ensures that any detected deviation is measured relative to the gravitational center of the downhole tool, thereby providing a stable and gravity-centric reference for re-centering actions. In other embodiments, the auto centralizermay utilize the gyroscopic center as the measurement point for detecting deviations. This approach enhances precision by aligning the monitoring process with the gyroscopic characteristics of the conveyanceduring well intervention operations. The flexibility to choose between various reference/measurement points allows the auto centralizerto adapt to varying conditions and requirements in different wellbore scenarios and different wellbore operations. For instance, if the downhole toolis heavier than a predefined weight threshold, then the measurement point may be chosen to be substantially close to the downhole toolor may even be the center of gravity of the downhole tool. In another example, if the downhole toolweighs less than a predefined weight threshold, the measurement point may be the gyroscopic center or any point between the gyroscopes and the downhole tool.
In one or more embodiments, initially determining the reference X and Y coordinates of the wellbore(and the casing) may include positioning the detection unitatop a reference valve, for example, the crown valve of the BOP(). Once the detection unitbecomes perfectly vertical and aligned with the centerline() of the wellbore, the orientation and reference coordinates will be recorded. The reference coordinates in terms of X and Y may represent the center of the casingand may be visually represented as a curvilinear path or a straight line. For example, the original drilling operation of the well may have captured the deviation of the wellborefrom true vertical, which can be found in what is called the Deviation Survey or Well Trajectory. Measuring the Deviation Survey involves leveraging a gyroscopic application. From the Deviation Survey, it is possible to calculate the X and Y coordinates that represent the center of the wellborefor each depth interval throughout the entire duration of the well intervention path. In an embodiment, such depth intervals may also be predetermined based on the characteristics of the casingand/or the intervention operations.
In some embodiments, the detection unitmay be programmed and otherwise configured to continuously monitor current (real-time) X and Y coordinates, ensuring a comprehensive assessment of the movement of the conveyanceduring the entire wellbore intervention operation. The gyroscopesallow for a synergistic analysis, considering both translational (X and Y coordinates) and rotational (angular deviations) components. Such a combined approach provides a detailed representation of the position of the conveyancewithin the wellbore(e.g., the casing). Moreover, in one or more embodiments, the auto centralizermay further incorporate one or more additional sensors or units for increased accuracy, without departing from the scope of the disclosure. In such embodiments, such sensors can include, but are not limited to, accelerometers, magnetometers, or any suitable sensing technology capable of contributing to the accurate determination of the deviation of the conveyance. Further, in at least one embodiment, the auto centralizermay include a pressure sensor to enable the system to dynamically adjust centralization in response to fluctuations in wellbore pressure.
Determining the deviation of the conveyancemay include comparing the reference X and Y coordinates of the wellbore(e.g., the casingor another tubing arranged within the wellbore) with the current (real-time) X and Y coordinates of the conveyanceas the conveyancetravels (descends) within the casing. This step may enable quantification of the deviation, offering insights into how far the conveyancehas deviated from its intended path within the casing. The quantification also enables determination of the combined thrust (force) required to re-center the conveyance, as discussed below.
In addition, determining the deviation of the conveyancemay further include determining if the current (real-time) X and Y coordinates of the conveyancehave deviated beyond a predetermined deviation threshold with respect to the reference X and Y coordinates. The auto centralizeris configured to adjustably set the predetermined deviation threshold to establish acceptable limits for deviation. The customization of predetermined deviation thresholds before beginning the wellbore intervention operation ensures that corrective measures are triggered only when the measured deviations exceed the predetermined deviation threshold.
In some embodiments, the predetermined deviation threshold can be about +/−0.05 inches from the reference coordinates (i.e., along X- and Y-axes). Further, in an example, the predetermined deviation threshold for detecting deviation is adjustable based on wellbore conditions and characteristics. For example, the threshold-based analysis may be crucial for distinguishing significant (unacceptable) deviations from minor variations in the position of the conveyance. If the current X and Y coordinates exceed the predetermined deviation threshold, that indicates a notable deviation from the expected path within the casing. This approach provides practical criteria for identifying deviations that may require attention or corrective actions, offering a systematic and proactive method for monitoring the trajectory of the conveyance.
As illustrated, the auto centralizermay further include a re-centering or “turbine-powered” unitconfigured to rectify (correct) deviations in the positioning of the conveyancewithin the casing. The re-centering unitfunctions as a dynamic response mechanism to promptly address any detected deviation and thereby ensure the continuous alignment of the conveyancealong its intended/planned path or the center of the casing. In some embodiments, as illustrated, the re-centering unitmay include one or more motorized fans, blades, turbines, or propellers(collectively referred to herein as “propellers”). As used herein, the term “propellers” refers to rotating blades or turbines powered by a motor. The propellersplay a pivotal role in providing controlled thrust in predetermined directions upon detection of a deviation beyond the predetermined deviation threshold.
As shown in the enlarged inset graphic of, the propellersmay include four propellers, namely, a first propeller, a second propeller, a third propeller, and a fourth propeller. In other embodiments, there may be only three propellersequidistantly spaced from each other (e.g., 120° apart), or more than four propellers, without departing from the scope of the disclosure. In some applications, the number of propellers-may depend on the weight of the downhole tool. For instance, a heavier payload may require a higher number of propellers-, and a lighter payload may require a lower number of propellers-
In some embodiments, each propeller-is powered and otherwise driven by a dedicated and discrete motor. In other embodiments, two or more of the propellers-may be powered or driven by the same motor. In example operation, the auto centralizermay activate the motor associated with some or all of the propellers-, resulting in a precisely controlled thrust that facilitates realignment of the conveyance(and the downhole tool) to its intended trajectory. Further, the propellers-can be selectively, sequentially, and/or simultaneously activated to precisely control the alignment of the conveyanceto the intended path. The coordinated action of the propellers-ensures an efficient and targeted response to deviations, enhancing the overall centralization process during well intervention operations.
In one or more embodiments, the auto centralizerincludes multiple motors used to drive different sets of propellers-. In such embodiments, each motor may be specifically associated with a particular set of propellers-. Upon detecting a deviation beyond the predetermined deviation threshold, the auto centralizermay selectively, sequentially, and/or simultaneously activate the motors corresponding to the respective set of propellers-. This approach provides independent control over each motorized propeller-, allowing for the generation of a controlled and combined thrust in distinct directions with different magnitudes based on the detected deviation. Alternatively, a single motor with a variable frequency drive can be employed. The variable frequency drive facilitates the adjustment of rotational speeds for different propellers-based on the nature and extent of the detected deviation. This dynamic capability allows the auto centralizerto modulate the rotational speed of individual propellers-, tailoring the thrust generated by each propeller-to the precise requirements of the realignment or re-centering process.
In some embodiments, the auto centralizermay provide an elongate housinghaving a first or “upper” endand a second or “lower” endopposite the upper end. The upper endmay be operatively coupled to the conveyance, and the lower endmay be operatively coupled to the downhole tool. The gyroscopesand the propellers-may be operatively and strategically coupled to the housingat a corresponding locations between the upper and lower ends. In some embodiments, as illustrated, the propellers-may be located near the downhole tooland the gyroscopes-may be located closer to the upper end. In other embodiments, however, the gyroscopes-may be located near the downhole toolso that the detected deviation of the conveyancerepresents most accurately the deviation of the downhole tool.
The design and configuration of the auto centralizermay take into consideration space limitations of common downhole tubulars (e.g., the casing, production tubing, etc.). For instance, existing logging tools can fit in casing having a diameter of about 3.5 inches. In an embodiment, the size of well intervention tools (and therefore the auto centralizer) may be adjustable and otherwise capable of being scaled up or down based on the different size limitations of the casing.
In an example where the casingexhibits a diameter of about 4.5 inches, an area of over 63 inches squared is available for design considerations of the auto centralizer. This space is sufficient to accommodate all the component parts of the auto centralizerand centralize the downhole toolby using the components described herein. Furthermore, as mentioned above, for different applications there can be a varying numbers of propellers-in line with one another to provide the necessary forces (thrust) needed to properly centralize the downhole tool.
Once the auto centralizeridentifies or senses a deviation beyond the predetermined deviation threshold, the auto centralizermay be programmed or otherwise configured to activate one or more of the propellers-selectively, sequentially, and/or simultaneously to generate controlled thrust in a specified direction, thus facilitating the precise realignment of the conveyancetowards the predefined center of the casing. This controlled and selective operation ensures an efficient and accurate response to deviations, which helps maintain optimal alignment throughout the wellbore intervention operation.
If the auto centralizerdetects a deviation in the position of the conveyance(or the position of the downhole tool) from the predefined center of the casing, the auto centralizermay selectively activate specific propellers-to generate thrust in a strategically chosen direction to counteract the deviation. For example, if the conveyance(or the downhole tool) deviates towards the right of the center of the casing, as viewed from the vantage point of, the auto centralizercan selectively activate one or more propellers-on the left side of the housingand thereby generate a thrust toward the leftward direction, effectively steering the conveyance(and the downhole tool) back towards the center by offsetting the determined deviation. The magnitude of the mechanical force or thrust generated by the activated propellers-may be proportional to the magnitude of the detected deviation. Similarly, the direction of the applied thrust may be dependent on the direction associated with the detected deviation. Alternatively, the auto centralizermay engage all of the propellers-simultaneously, each propeller-contributing an individual thrust in a designated direction, and thereby resulting in a combined force/thrust that facilitates re-centering of the conveyancein a time-efficient manner.
In an embodiment, the re-centering process may involve multiple re-centering sub-steps each of which reduces the determined deviation in a step-wise manner. In such embodiments, the re-centering process may be iterative and carried out until the deviation falls within accepted limits of the predetermined deviation threshold. Each re-centering sub-step may correspond to an individual or combined thrust from one or more propellers thereby sequentially reducing the deviation in steps and achieving the centralization of the downhole toolin a time and energy efficient manner.
In an embodiment, as the conveyancetraverses the casing, the auto centralizercontinuously monitors its current (real-time) X and Y coordinates. The frequency of such monitoring (and associated computations) can be customized based on the specific requirements and characteristics of the wellboreand the intervention operation, among other factors. For instance, very frequent monitoring may be preferred in situations where deviation thresholds are sensitive or set to very low values. This customization allows the auto centralizerto adapt its monitoring frequency to the specific conditions of the wellbore and/or intervention operations, ensuring a tailored and responsive approach.
In some embodiments, the auto centralizermay include or be communicably coupled to a control unitin communication with the detecting unitand the re-centering unit. In particular, the control unitis configured to receive and/or send signals to the detecting unitand the re-centering unit, and thus may be configured to control operation of the auto centralizer. In some embodiments, the control unitmay be remotely located, such as at the well surface location() and communicate with the auto centralizervia any wired or wireless communication means. For example, the control unitmay communicate with the auto centralizervia a wire or cable run along or through (within) the conveyance. In other embodiments, however, the control unitmay be arranged within or coupled to the housingand otherwise located near the detecting unitand the re-centering unit.
The control unitis configured to ensure a responsive and accurate realignment of the conveyancebased on deviations detected during its traversal within the casing. The control unitis further configured to continuously receive signals indicative of the current position of the conveyanceand deviations from the detecting unitfor logging and pattern recognition purposes.
In some embodiments, it is the control unitthat is programmed to control monitoring of the current X and Y coordinates of the downhole toolas the conveyancetraverses the casing. The control unitmay then be programmed or otherwise configured to compare the real-time coordinates with the reference X and Y coordinates of the casingand determine any deviations beyond a predetermined deviation threshold with respect to the reference coordinates. Upon detection of such deviations, the control unitmay be programmed or otherwise configured to activate (or send an activating signal to) the propellers-. In at least one embodiment, the control unitensures a continual feedback loop based on signals received from the detecting unit, and dynamically adapts to changes in the conveyancetrajectory within the casingby sending activating signals to the re-centering unit. This real-time responsiveness facilitates prompt and accurate adjustments, ensuring that the auto centralizeradapts effectively to variations in the conveyanceor the downhole toolposition.
In some embodiments, the control unitmay be configured to regulate operation of each propeller-, thus facilitating movement of the conveyanceand/or the downhole tooltowards the predefined center of the casing. Further, the control unitmay determine an angular force required by the propellers-to re-center the conveyanceand/or the downhole tool. The control unitselectively operates each motorized propeller-to generate the controlled thrust, ensuring a precise and effective realignment of the conveyance. Additionally, the control unitmay be configured to modulate the speed and direction of rotation for each motorized propeller-. This precise modulation enables the generation of thrust in a targeted manner, which may be crucial for steering the conveyanceand/or the downhole tooltowards the central axis of the casing. This corrective action, aligned with the nature of the detected deviation, not only ensures timeliness but also enhances the overall efficiency of the realignment process.
In some embodiments, there may be multiple auto centralizerswith corresponding detecting unitsand re-centering unitsinstalled along the length of the conveyanceat multiple and pre-selected locations. In such embodiments, each auto centralizermay be in communication with the control unit, which provides centralized control of each auto centralizer. The control unitmay be configured to send/receive signals from each gyroscopic centralizer tooland can control the re-centering process not just of the downhole toolat one end of the conveyancebut also of the entire or a predetermined length of the conveyance. Such an arrangement may be useful in scenarios where the downhole toolis heavier than a weight threshold.
Including multiple auto centralizersmay also be useful in applications where there is a higher risk of equipment failure during the wellbore intervention operation. Instead of lifting the conveyanceto the well surface() for repair operations, it may be desirable to continue with the wellbore intervention operation, if possible. Therefore, if one auto centralizerfails during the wellbore intervention operation, the other (remaining) auto centralizersmay be used for continuous monitoring and re-centralization without having to stall the intervention operation or retrieving the conveyanceto the well surface. As will be appreciated, including multiple auto centralizersat different (spaced) locations along the conveyancemay provide a highly coordinated maneuvering capability of the conveyanceand the downhole toolleading to higher re-centering accuracies.
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October 23, 2025
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