IADC/SPE 87170 A Pressure Activated Deployment System for Openhole Memory Logging Tools and its Application in Directional

Wells
M. C. Spencer, S. C. Ash, SPE and P. A. S. Elkington, SPE, Reeves Oilfield Services

Copyright 2004, IADC/SPE Drilling Conference This paper was prepared for presentation at the IADC/SPE Drilling Conference held in Dallas, Texas, U.S.A., 24 March 2004. This paper was selected for presentation by an IADC/SPE Program Committee following review of information contained in a proposal submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the International Association of Drilling Contractors or Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the International Association of Drilling Contractors or Society of Petroleum Engineers, their officers, or members. Papers presented at IADC/SPE meetings are subject to publication review by Editorial Committees of the International Association of Drilling Contractors and Society of Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the International Association of Drilling Contractors and Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300 words; illustrations may not be copied. The proposal must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract Openhole memory logging was introduced in 1999 as a more efficient alternative to pipe conveyed wireline logging. It was developed subsequently into a shuttle system that conveys logging tools inside drillpipe, and which provides formation evaluation logs after drilling to supplement basic real-time logging-while-drilling (LWD) data. The original shuttle design used a dart pumped from surface to move the logging string into open hole after the assembly reached TD. In a new development, the dart has been eliminated together with the associated pumping time. In its place is an electro-mechanical pressure activated release mechanism capable of simple twoway communication. The method has been used in trials to activate and deploy logging tools downhole, and to return status information to surface. It has the potential to be developed further for post-drilling real-time data transmission, and is a key component in a repeat formation pressure tester being developed for memory operations. Introduction Memory logging is commonplace in cased hole operations, and openhole LWD relies on memory to store data that cannot be pulsed back to surface in real-time. The openhole memory logging described here, however, uses standard wireline logging tools operated in memory mode without a wireline. Quad-combo memory measurements were introduced commercially in 1999. One motivation was to eliminate large and costly wireline units and to reduce the number of people needed to operate the equipment. A further motivation was to provide new conveyance options for high angle and horizontal wells, and wells with bad hole conditions. In low angle wells wireline tools rely on gravity to get to TD, but in high angle, horizontal and extended reach wells

they are conventionally pushed into the well on drillpipe in pipe-conveyed-logging (PCL). The system described here the well shuttle - conveys the tools inside drillpipe, and so protects the tools while running-in. In doing so it exploits a key feature of the logging tools - namely their small size. In shuttle operations the logging tools are pumped out of drillpipe at TD. The top of the tool string is retained in a latch sub, and data are acquired while tripping the pipe out of the hole. In contrast with wireline PCL operations the well can be circulated and pipe rotated throughout, and non-return valves included in the BHA reduce the risks associated with pressure kicks. Removing the wireline also makes it easy to set pipe rams. The BHA is typically configured with a reamer shoe to assist getting on bottom (particularly in bad hole conditions), and the logging programme may be carried out concurrently with a check trip or hole cleaning operation. These features give shuttle an overwhelming advantage relative to wireline PCL for standard formation evaluation measurements. Potentially more significant is its role as an alternative to LWD. Basic measurement while-drilling logs (such as navigation and gamma ray) are likely to be run in all directional wells, but the real-time formation evaluation elements of LWD (density, neutron porosity and acoustic velocity in particular) are required only in the minority of wells that are petrophysically steered. More generally it is the potential for reducing costs by eliminating extra runs in the hole that drives the use of LWD. The shuttle system has a role in this scenario because the relative reliability, costs, data quality and lost-inhole charges of wireline-style memory tools are advantageous relative to LWD. Description of the Shuttle Conveyance System The shuttle comprises the logging tools, drillpipe, and mechanisms for retaining and releasing the tools (Fig. 1). An open-ended reamer bit can be included to aid re-entry and to assist conditioning of the well. The logging string is housed inside drillpipe at surface and remains inside until tripped to TD. There is no wireline. In the first shuttle system (introduced December 2001) a dart pumped from surface released the tools and caused them to move into open hole(1). The system is simple and robust, but in deep or extended reach wells it may take up to 45 minutes for the dart to reach TD. The new system eliminates the delay. The logging string is conveyed close to TD as before. Once in position, the mud pumps are used to generate a short sequence of pressure

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IADC/SPE 87170

pulses, and these are detected by an electric release mechanism located above the tools. If the sequence is recognised as valid, the mechanism opens retaining latches that allow the tools to be pumped into open hole. A pulse is returned to surface once the tools have landed, and a signalling mechanism returns tool status information back to surface. As before, data are acquired while tripping out. Three shuttle sizes have been developed: 6-inch OD for wells with a minimum 8-inch bit size, 4-inch OD for wells with 6-inch minimum bit size, and a 3-inch OD variant for wells as small as 4-inches bit size. In each case the maximum recommended rotation rate is 60 rpm (optimum performance of the reamer bit is around 30 rpm). The maximum circulation rate varies between 3 and 40 bbl/min depending on the release mechanism and size of the shuttle. Mechanical Components These are: Latching Sub. The latching sub retains the logging tools inside the last section of drillpipe as the string is run to TD. It is in two parts: the logging tools and the running tool (that will move the tools into openhole once TD is reached) are made up into the lower latching sub, then the upper latching sub is added to hold the assembly in place. Running Tool. This locks the logging tools to the latching sub until activated by the electric release mechanism (Fig.2). It comprises a series of concentric sliding sleeves, circulating ports and damping springs that work with mud pressure to move the logging tools towards open hole in a controlled manner. In so doing it also generates a pressure signature that confirms proper deployment (Fig. 3). Referring to Fig 2, when the shuttle is running-in the well the valve sleeve (D) covers the upper circulation ports (E), and mud flows over the logging string to exit via the reamer (or mule) shoe. When the logging string is ready to be deployed, the locking mechanism (B) is disengaged by the action of the central hollow drive tube (G) that runs the length of the tool. It is driven uphole by the electric release tool (responding to commands from the surface). Once free, mud pressure acts on a pair of payload seals (A) to cause the running tool and logging string to move forwards inside the drillpipe. The rate of deployment is controlled by the pumping rate. If the rate of deployment exceeds the planned rate, the logging tools are protected from shock damage by a landing spring (C). During deployment the circulating ports (E and I) remain closed. After the running tool contacts the landing collar pressure increases against a pre-compressed spring (F). At a predefined incremental increase in pressure the spring moves and circulation is re-established through the circulation ports. The pressure needed to move the spring is seen at surface. Should circulation fail to re-establish (due to the circulating ports becoming blocked), then it is possible to prevent the drillpipe from being pulled wet by breaking shear pins (H) with a further pre-defined increase in mud pressure. Electric Release and Signalling Tool. This comprises an electric motor, mud column pressure sensor and processing electronics. Prior to each job the tool is programmed with the magnitude and duration of the pressure pulses that will be

used during the job to release the logging string (Fig 3). Once in the hole (and after a pre-set delay) it begins to monitor the mud pressure. On receipt of the appropriate pressure signature it engages the running tool drive tube, and moves it so as to disengage the latch and activate the payload seals. The running tool (with logging string attached) is now free to be pumped into open hole. The electric release also activates the logging string (which until now has been dormant to conserve battery power). In addition to the large movement used to actuate the drive tube, small bi-directional movements can be made, controlled by the signalling part of the mechanism. This modulates the flow of mud by moving a piston inside a slotted sleeve to partially occlude a set of circulation ports. The piston position is controlled precisely, allowing the pressure to change in small increments. The pattern of pressure change is recorded at surface, and the input signal re-constituted. This function is being used initially to return tool status information to surface (to confirm that the logging string has powered-up successfully). It is also designed to transmit log data, including data from a memory formation pressure tester currently under development. For this application the system need transmit only the shape of a log curve, not its absolute values (which are recorded in memory). Constraining its purpose in this way allows faster transmission than is possible with binary mud pulse technology. Float Valve Sub. The float valve sub is run above the latching sub, and contains two non return flapper-type valves to prevent well pressure forcing the logging tools up inside the drillpipe in the event of a kick. Reamer Bit or Mule Shoe. The reamer bit is an open-ended hole opening bit that assists re-entry and allows the logging string to pass into open hole. If the reamer is not required, a mule shoe will be run as hole finder and thread protector. When the logging string includes a density measurement, its caliper is opened automatically as it exits the shuttle. Openhole Memory Logging Tools The logging string has an outside diameter of 2 inches small enough to be conveyed inside the slimmest shuttle variant (Fig. 4). The tools were developed initially as more efficient replacements for conventionally-sized wireline tools, and are qualified for hole sizes up to 12 inches (16 inches in the case of resistivity measurements). Measurement performance was monitored in 7,000 wells over a four-year period before battery and memory modules were added for wireless conveyance. They also provide formation evaluation measurements in the Through Bore drilling system (2). The primary measurements are: array induction, dual laterolog, shallow high resolution resistivity, formation density with photoelectric (Pe) and caliper curves, natural gamma ray, neutron porosity and acoustic slowness (inverse velocity). Ancillary measurements include two-arm caliper, navigation and temperature. A repeat formation pressure tester currently available in wireline mode is being developed for wireless operations. Dipole sonic (to determine shear velocities) and a resistivity imaging tool are under development. Tools are rated for continuous operation to 257 F and 12.5 kpsi.

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Battery life is assessed for each job based on the tool string configuration and predicted borehole temperature (battery life increases with temperature up to about 250 F). A single module powers a triple-combo (induction, gamma, Pe-density and neutron porosity) for 19.3 hours at 140 F - sufficient for most operations. Extended life battery packs are used for long duration operations and more complex tool strings. Second generation battery packs (that restrict power consumption while running-in) substantially increase the downhole operating time, and satisfy the additional power requirements of planned future tools. The memory module performs the same data capture function as the wireline surface system except that data are requested from the tools at regular time increments rather than regular depth increments. Each standard module has sufficient capacity to record 20 hours of triple-combo data at 500millisecond sampling. Larger modules allow recording time to be extended, and the recording of high density data sets such as acoustic waveforms. Surface Equipment Data from the memory module is downloaded to a PC via a USB port. The only other electrical surface equipment is a plotter for hard copy. No wireline unit is needed. Two source containers and a tool rack complete the surface kit. Logging Procedure Pre-job calibration and checking of the individual logging tools matches wireline operations except that a communications umbilical is used in place of a wireline. These procedures do not interrupt normal rig operations. The tools are then configured into a logging string, including battery and memory modules, with ancillary positioning equipment (such as swivels and knuckles) as appropriate. The logging process starts after the well has been drilled and the bit has been tripped back to surface. A shuttle reamer bit or mule shoe is held in the slips. Sufficient drillpipe to contain the logging string is lifted and made up to the landing sub before being run into the hole and also held in the slips. The lower latching sub is then torqued-up to the drillpipe. At this point the logging string, electric release and running tools are introduced into the pipe, and the battery pack activated. This starts a sequence of internal diagnostic tests that check the proper functioning of the logging string as a whole. LED displays on the side of the memory sub allow the test sequence to be monitored. Upon successful completion of the tests all the logging tools are powered down except for the memory and electric release tool. The upper latching sub is now made up to the lower latching sub. Finally the float valve is added, and the shuttle is complete. A crossover to the remaining drill string is added as required. The shuttle assembly is now run to bottom to tag TD. This is done at normal bit-tripping speed. The well can be circulated and drillpipe rotated and reciprocated at any time during this part of the operation. If a well control situation occurs the pipe rams can be closed completely - there is no wireline in the way. At TD the well is circulated to remove cuttings and condition the hole before logging takes place.

A length of pipe is pulled from the well equivalent to the length of the logging string after deployment from the shuttle. A status pulse transmitted from the surface initiates diagnostic checks in the logging string, and the check result is returned to surface. After a successful check the shuttle is ready to receive additional pulses to begin the release sequence. Typically, two pulses are required, each of a minimum duration and magnitude (Fig. 2). The time between pulses (plus or minus a tolerance) is also defined. The sequence is pre-programmed into the release tool, and replicated in a hand-held surface panel. The mud pumps are now driven according to the sequence indicated on the panel. The electric release tool releases the running tool and logging string, which moves towards open hole. As the landing collars on the running tool and landing sub engage, a large spring restrains the tools, and an increase in mud pressure is noted at surface. An over pressure of 500 psi on the spring allows a sleeve to slide with the tools, exposing a set of circulating ports that allow the mud pressure to fall again to signal landing. It also allows mud to flow back into the borehole from the drillpipe as it is pulled back to surface. If these ports should become blocked, a further pre-defined increase in mud pressure will break shear pins within the landing sub, and a second set of ports will open to ensure that pipe is not pulled wet. Log data is acquired as the shuttle is pulled back to surface. When the tool string re-enters casing a signal from the induction tool can (if required) close the caliper arm of the density tool to minimize wear on the density skid. Sending the appropriate pulse sequence can also close the caliper. After recovery at surface the log data are downloaded from the memory module to a PC. Applications Shuttle systems with dart deployment have been operating commercially since December 2001. In most cases they have been used in high angle, horizontal and other directional wells where the duration and safety of conventional PCL operations has been a concern(3), or where the total cost of LWD formation evaluation data acquisition has been high relative to shuttle. In a smaller number of cases they have been used where bad hole conditions impede wireline conveyed tools (in both low and high angle wells). The advantages relative to quad-combo logging by conventional pipe conveyance are overwhelming in most situations. In some circumstances it is particularly advantageous: In high angle wells where previous practice was to attempt wireline conveyance into build sections followed by PCL in the deeper intervals, the shuttle acquires data from the entire openhole interval in one pass. Long horizontal intervals are exceptionally time consuming to log with PCL if the casing shoe and build section are at shallow depth (because the side-door needs to be re-positioned to avoid having the wireline in open hole). The shuttle allows data to be acquired in one pass. The dart variant of the shuttle has displaced LWD formation evaluation measurements primarily where the risk

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of losing high cost LWD assemblies has been high, and where advantage can be taken of the shuttle's ability to acquire data concurrently with hole cleaning operations. The pressure activated variant has the same capabilities as its predecessor, and has three additional benefits: Deployment time is reduced further by removal of the need to pump a dart from surface. It has simplified the implementation of the 3-inch OD shuttle. This is because the dart's pumping seals need to perform over a range of internal pipe diameters in the same string. The smaller the final pipe size the more difficult it becomes to achieve this, particularly in a horizontal orientation. The signalling capability of the new system is an important element in realising a memory formation pressure tester. Results Results from the dart variant of the well shuttle have been reported elsewhere(1). It operated routinely for two years prior to the start of development work on the electric release and signalling mechanisms, so confidence in the basic systems is high. The new components were tested in a 1.4-Km long horizontal flow loop (built specifically for the purpose of evaluating shuttle-related technologies), and the complete system was evaluated in a horizontal test well in Aberdeen, Scotland. This first phase of testing has been completed successfully, and extended trials are due to begin early 2004. The testing was concerned largely with the detection and decoding of the pressure signals. Superimposed on the desired signals is noise from the mud pumps, but even with a noisy pump the magnitude and duration of both the uphole and downhole signals is unambiguous (Fig 5). The performance of the signalling mechanism was also tested in the flow loop. It comprises the signalling ports, a signalling piston and servo-controlled signalling motor (items I, J and K in Fig 2). Mud circulating through the signalling ports is restricted by the signalling piston (Fig 6). The mechanism causes the pressure in the mud to change approximately linearly with piston position (Fig 7). Although its primary function is to transmit simple status information, the behaviour can be exploited to transmit an analogue representation of the log data uphole while logging. In this mode its purpose is to provide quality control information during (for example) memory formation pressure testing. . Memory Formation Pressure Tester The memory formation pressure tester is at the early stages of testing, but results are encouraging. Any shuttle deployed tester needs to be small. In 2002 a 2.4-inch OD tool was introduced for wireline operations. It has an unusual setting mechanism that allows it to open into 10inch diameter wells (Fig 8), and a long-reach variant opens to 14-inches. After two years of exposure to commercial operations it has been modified for shuttle deployment. In memory mode a correlation log is transmitted while running-in (before the tools have been deployed). After the tests points have been identified, the tester is deployed in the usual way and moved into position using the correlation log as

a guide. The setting and measurement cycle is started when a sequence of mud pump generated pressure pulses is decoded by the electric release tool. Circulation can be maintained throughout, and a swivel in the logging string allows pipe to be rotated if necessary. Drawdown begins after the tool is set, and measurement status information is sent uphole. The arms are retracted after completion of a measurement cycle, or on receipt of further commands from surface. The full test data is returned to surface in the memory module. Conclusions Shuttle conveyed openhole memory logging tools are being deployed routinely using the pumped dart release mechanism. An electric release mechanism has now been developed that eliminates the time needed to pump the dart, and which allows measurement status information to be transmitted to surface while logging. The method affords reliable, safe access to high angle wells and wells with bad hole conditions. The system replaces quad-combo PCL logging. The specific benefits include greater reliability resulting from wireless operation and greater levels of protection, greater speed due to tools being run-in at tripping speed and pipe being rotated and reciprocated to assist reaching bottom. Well control can be achieved without terminating the logging operation, and wells can be conditioned by circulating bottoms up at TD. Circulation is maintained during logging. Elimination of the wireline unit has a positive impact on operating costs. The original shuttle system was used as an alternative to the formation evaluation element of LWD in locations where the risked cost of LWD is disadvantageous. The pressure activated release mechanism widens the cost differential further. It has enabled a simpler implementation of a slim 3inch OD shuttle for wells as small as 4-inches bit size. This broadens the range of well types for which the shuttle is the only economically viable means of acquiring formation evaluation data. References
1. Elkington, P. A. S., Spencer, M. C. & Spratt, D. L., "The Development and Testing of A Garaged Open Hole Logging System for High Angle Wells and Bad Hole Conditions", paper SPE 77560 presented at SPE Annual Technical Conference, San Antonio, Texas, 29 September2 October 2002.. 2. Runia, J., Murphy, E., Boyes, J., Sutherland, G., Sim, D & Brown, P., "Through Bore Drilling Systems: a New Drilling Option", paper SPE 79794 presented at the SPE/IADC Drilling Conference, Amsterdam, 19th - 21st February, 2003. 3. Spratt, D. L., "Benefits of Obtaining Well Log Data in Horizontal Wells in the WCSB", presented at the Pet Soc CIM/SPE 8th One Day Horizontal Well Conference, Calgary, 7th Nov. 2001.

SI Metric Conversion Factors in. x 2.54* E+01 = mm psi x 6.894 757 E+03 = Mpa bbl x 1.589 873 E-01 = m3 *Conversion factor is exact.

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Float Valve & Latching Sub

Running Tool

Electric Release & Signalling Tool

Battery

Memory & Processing

Logging Tools

Landing Collar

Uphole

Downhole

Figure 1. Overview of the shuttle system

K Signalling Tool

Running Tool

Figure 2. Running and signalling tools. A - payload seals, B - latch, C - landing spring, D - valve sleeve, E - upper circulation ports, F - pre-compressed spring, G - drive tube, H - shear pins, I - signalling ports, J - signalling piston, K - signalling motor.

tools released Ppump2

Pressure

tools land

Ppump3

tool status OK

Ppump1 Tp

tool running
Time

Figure 3. Pressure pulses in the mud column immediately before, during and after the release of the logging tools. In a typical release sequence, Ppump2 and Ppump3 are 500 psi above ambient pressure level, Ppump1 , each with a duration TP of 30 seconds.

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Figure 4. Compact 2 inch memory logging tools. From left to right: array induction, photodensity, high resolution shallow resistivity, dual neutron porosity, gamma ray (with ancillary measurements). Not shown are acoustic velocity, and dual laterolog.

900 800 700 600 Pressure (psi) 500 400 300 200 100 0 0 100 Time (seconds) 200 300

Figure 5. Pressure pulses recorded by the electric release tool during a horizontal flow loop test.

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Figure 6. Mud flowing through the signalling ports.

600

500 Piston position (relative) 0 900 100 200 Time (seconds)

Figure 7. Signalling tool operation. The position of the signalling piston controls the pressure in the mud column. The piston is designed such that pressure changes approximately linearly with position.

Pressure (psi)

400

300

200 300

Figure 8. Memory repeat formation pressure tester in the arms-open position. The tool closes to 2.4-inches diameter.

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