# Patent

## Title
Wellbore formation evaluation system and method

## Abstract

A formation evaluation tool positionable in a wellbore penetrating a subterranean formation is provided. The formation evaluation tool includes a cooling system adapted to pass a cooling fluid through electronics in the formation evaluation tool whereby heat is dissipated therefrom, the electronics has at least one gauge, a fluid communication device having an inlet adapted to receive the formation fluid and a flowline operatively connected to the fluid communication device and the gauge for placing the formation fluid in fluid communication therewith whereby properties of the formation fluid are determined.

## Background
This is a divisional of U.S. patent application Ser. No. 11/284,077, filed Nov. 21, 2005 now U.S. Pat. No. 7,428,925, the content of which is incorporated herein by reference for all purposes.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatuses and methods for evaluating subsurface formations in wellbore operations. More particularly, the present invention relates to wellbore systems for performing formation evaluation, such as testing and/or sampling, using a downhole tool positionable in a wellbore penetrating a subterranean formation.
2. Background of the Related Art
Wellbores are drilled to locate and produce hydrocarbons. A downhole drilling tool with a bit at an end thereof is advanced into the ground to form a wellbore. As the drilling tool is advanced, a drilling mud is pumped from a surface mud pit, through the drilling tool and out the drill bit to cool the drilling tool and carry away cuttings. The fluid exits the drill bit and flows back up to the surface for recirculation through the tool. The drilling mud is also used to form a mudcake to line the wellbore.
During the drilling operation, it is desirable to perform various evaluations of the formations penetrated by the wellbore. In some cases, the drilling tool may be provided with devices to test and/or sample the surrounding formation. In some cases, the drilling tool may be removed and a wireline tool may be deployed into the wellbore to test and/or sample the formation. In other cases, the drilling tool may be used to perform the testing or sampling. These samples or tests may be used, for example, to locate valuable hydrocarbons.
Formation evaluation often requires that fluid from the formation be drawn into the downhole tool for testing and/or sampling. Various fluid communication devices, such as probes, are extended from the downhole tool to establish fluid communication with the formation surrounding the wellbore and to draw fluid into the downhole tool. A typical probe is a circular element extended from the downhole tool and positioned against the sidewall of the wellbore. A rubber packer at the end of the probe is used to create a seal with the wellbore sidewall. Another device used to form a seal with the wellbore sidewall is referred to as a dual packer. With a dual packer, two elastomeric rings expand radially about the tool to isolate a portion of the wellbore therebetween. The rings form a seal with the wellbore wall and permit fluid to be drawn into the isolated portion of the wellbore and into an inlet in the downhole tool.
The mudcake lining the wellbore is often useful in assisting the probe and/or dual packers in making the seal with the wellbore wall. Once the seal is made, fluid from the formation is drawn into the downhole tool through an inlet by lowering the pressure in the downhole tool. Examples of fluid communication devices, such as probes and/or packers, used in downhole tools are described in U.S. Pat. Nos. 6,301,959; 4,860,581; 4,936,139; 6,585,045; 6,609,568 and 6,719,049 and US Patent Application No. 2004/0000433.
Once the fluid enters the downhole tool, it may be tested, collected in a sample chamber and/or discharged into the wellbore. Techniques currently exist for drawing fluid into the downhole tool and/or performing various downhole operations, such as downhole measurements, pretests and/or sample collection of fluids that enter the downhole tool. Examples of such techniques may be found in U.S. Pat. Nos. 4,860,581; 4,936,139; 5,303,775; 5,934,374; 6,745,835 3,254,531; 3,859,851; 5,184,508; 6,467,544; 6,659,177; 6,688,390; 6,769,487; 2003/042021; 2004/0216874; and 2005/0150287.
In some cases, the wellbore environment may be exposed to extremely high temperatures and/or pressures which may cause electronics and other tool components to fail. Techniques for cooling instrumentation, such as electronic circuits, in a downhole tool are described, for example, in U.S. Pat. Nos. 5,701,751; 6,769,487 and US 2005/0097911.
Despite the development and advancement of formation evaluation techniques in wellbore operations, there remains a need to provide a formation evaluation system capable of operating in even the harshest wellbore environments having extreme temperatures and/or pressures. It is desirable that such a system be capable of efficiently cooling electronics in the downhole tool. It is further desirable that such a system eliminate, reduce and/or protect components that are subject to failure in harsh wellbore conditions. Such a system preferably provides one or more of the following among others: a fluid flow system that does not require a pump to draw fluid into the tool, consolidated electronics for efficient cooling, gauges (such as formation fluid sensors) located with or near the consolidated electronics for cooling, pressure balanced sample and/or dump chambers and increased cooling efficiency.
SUMMARY OF THE INVENTION
In at least one aspect, the present invention relates to a formation evaluation tool positionable in a wellbore penetrating a subterranean formation. The formation evaluation tool includes a cooling system adapted to pass a cooling fluid through electronics in the formation evaluation tool whereby heat is dissipated therefrom, the electronics comprising at least one gauge, a fluid communication device having an inlet adapted to receive the formation fluid and a flowline operatively connected to the fluid communication device and the at least one gauge for placing the formation fluid in fluid communication therewith whereby properties of the formation fluid are determined.
In another aspect, the invention relates to a method of performing formation evaluation via a downhole tool positioned in a wellbore penetrating a subterranean formation. The method involves removing heat from electronics in the downhole tool by passing a cooling fluid through the electronics, the electronics comprising at least one gauge, establishing fluid communication between a fluid communication device and the formation, the fluid communication device having an inlet adapted to receive a formation fluid from the formation, establishing fluid communication between the inlet and the at least one gauge via a flowline and measuring at least one parameter of the formation fluid via the gauge.



BRIEF DESCRIPTION OF THE DRAWINGS
So that the above recited features and advantages of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a side-elevational, partial cross-sectional view of a downhole tool positioned in a borehole penetrating a subsurface formation.
FIG. 2 is a schematic view of a portion of the downhole tool of FIG. 1 depicting a formation evaluation system and a cooling system.
FIG. 3A shows a schematic, partial cross-sectional view of an exemplary formation evaluation system for the downhole tool shown in FIG. 2.
FIG. 3B shows a schematic, partial cross-sectional view of another exemplary formation evaluation system for the downhole tool shown in FIG. 2.
FIG. 4 shows a schematic, partial cross-sectional view of an exemplary cooling system for the downhole tool shown in FIG. 2.



DETAILED DESCRIPTION OF THE INVENTION
Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. In describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
Referring to FIG. 1, an example environment within which the present invention may be used is shown. The downhole tool 10 of FIG. 1 is a wireline tool deployed into a borehole 14 and suspended therein adjacent a subsurface formation 15 with a conventional wire line 16 (or conductor or conventional tubing or coiled tubing) below a rig 17. Mudcake 40 lines the wellbore wall 38. While an open hole wellbore with mudcake is depicted, it will be appreciated that this downhole tool may be used in open or cased wellbores. The downhole tool 10 may be a formation evaluation tool such as the example wireline tool depicted in U.S. Pat. Nos. 4,936,139 and 4,860,581.
While FIG. 1 depicts a modular wireline sampling tool for collecting samples, the downhole tool 10 can be any downhole tool capable of performing formation evaluation, such as a drilling, casing drilling, completions, coiled tubing, robotic tractor or other downhole system. Additionally, the downhole tool 10 may have alternate configurations, such as modular, unitary, autonomous and other variations of downhole tools.
The illustrated downhole tool 10 is provided with various modules and/or components, including, but not limited to a probe module 24, a sampling module 26 and an electronics module 30. The probe module includes a probe assembly 32 and backup pistons (or loading pistons, bow spring, etc.) 42.
Referring to FIG. 2, a portion of the downhole tool of FIG. 1 is shown in more detail. The components of the modules of FIG. 1 are also shown in more detail. As shown, these components are in specific modules. However, these components may be positioned in one or more modules or drill collars, or in a unitary tool.
The electronics module 30 includes electronics 37 and a cooling system 39. Cooling system 39 includes a cooling driver 39a and a cooling flow unit 39b. The sampling module 26 includes a sample chamber 44. The probe module 24 includes a probe assembly 32, a conduit system 33 and backup pistons 42.
The probe assembly 32 of the probe module 24 includes a fluid communication device 36 for establishing fluid communication between the downhole tool 10 and the subsurface formation 15 so that fluid can be drawn from the formation 15 into the downhole tool 10 for testing and/or sampling. While the fluid communication device depicted is a probe, dual packers may also be used. Examples of probes and/or packers used in downhole tools are described in U.S. Pat. Nos. 6,301,959; 4,860,581; 4,936,139; 6,585,045; 6,609,568 and 6,719,049 and US Patent Application No. 2004/0000433.
The probe 36 is preferably extendable from the downhole tool 10 for engagement with a well bore wall 38. The probe 36 is operatively connected to the conduit system 33 for drawing fluid therein. Pretest piston 41 is operatively connected to the conduit system for performing pretests. Examples of pretest techniques are depicted in U.S. Pat. No. 6,832,515, assigned to the assignee of the present application.
The conduit system 33 includes internal fluid flow lines that divert fluid from the probe to various positions in the downhole tool. As shown, a first portion 33a of the conduit system extends from the probe into the downhole tool. A second portion 33b extends from the first portion to the electronics module 30. A third portion 33c extends from the first portion to the sampling module 26. A variety of flowline configurations may be used to facilitate fluid communication throughout the downhole tool 10.
While the portions of conduit system 33 is depicted in FIG. 2 as leading from the probe 36 to certain portions of the tool, such as sampling module 26, it will be appreciated by one of skill in the art that the conduit system 33 can include other paths or passages. For example, another passage (not shown) can lead from the probe 36 through the downhole tool 10 to an exit port (not shown) so as to enable transferring of formation fluid directly to the borehole 14, such as during a clean-up operation. The conduit system 33 also preferably includes valves to enable the selective directing of the formation fluid as it flows into and through the downhole tool 10. Additional valves, restrictors, sensors (such as gauges, monitors, etc.) or other flow control or measuring devices may be used as desired.
The sampling module preferably includes at least one sample chamber 44. A variety of sample chambers may be used. Examples of known sample chambers and related techniques are depicted in U.S. Pat. Nos. 4,860,581; 4,936,139; 5,303,775; 5,934,374; 6,745,835 3,254,531; 3,859,851; 5,184,508; 6,467,544; 6,659,177; 6,688,390; 6,769,487; 2003/042021; 2004/0216874; and 2005/0150287.
FIGS. 3A and 3B depict sampling systems 34, 34a usable in the sample module 26 of the downhole tool of FIGS. 1 and 2. FIG. 3A depicts a sampling system 34 with a pressure compensator 35. FIG. 3B depicts a sampling system 34a with a dump chamber. Like other components in the downhole tool described herein, the components of the sampling systems are preferably adapted to operate in harsh conditions.
The sampling system 34 of FIG. 3A includes two sample chambers 44a and 44b and a pressure compensator 35. The sample chambers are adapted to accept and retain an amount of fluid transferred thereto. As shown in FIG. 3A, the sample chambers include a first variable volume (hereafter referred to as a sample cavity 48a, 48b), and a second variable volume (hereafter referred to as a buffer cavity 50a, 50b). The sample cavities 48a, 48b are adapted to receive and store fluid. The buffer cavities 50a, 50b are adapted to receive and store a buffer fluid. Examples of fluids that may be used as the buffer fluid include oil, water and air. However, those skilled in the art will appreciate that other types of fluid may be used as the buffer fluid without departing from the spirit of the invention.
The sample cavity 48a, 48b and the buffer cavity 50a, 50b of the sample chamber 44a, 44b are separated and defined by a movable piston 52a, 52b, or other fluid separator such as a diaphragm or the like, disposed there between. The piston is adapted to slidably move along the interior of the sample chamber resulting in a change in the volume on the sample cavity and the buffer cavity of the sample chamber.
Third portion 33c of conduit system 33 leads from the probe 36 through the downhole tool 10 to the sample chambers 44a and 44b. As shown in FIG. 3A, multiple sample chambers 44a, 44b and corresponding flowlines 33c1, 33c2 and valves 46, 47 are provided. Preferably valves 46, 47 are positioned along flowlines 33c1, 33c2, respectively, of the conduit system to selectively divert formation fluid to the sample chambers 44a and 44b. While FIG. 3A depicts a preferred arrangement of valves and conduits, it will be appreciated by one of skill in the art that the arrangement may be varied. For example, flowlines and/or valves may be provided for one or more sample chambers. Additionally, such flowlines and/or valves may be positioned along conduit system 33 closer to probe 36. Other variations may also be envisioned.
The sample chambers 44a and 44b are arranged in fluid communication with third portion 33c of the conduit system 33. The sample chambers may be positioned in a variety of locations in the downhole tool. Preferably, the sample chambers are positioned for efficient and high quality receipt of clean formation fluid. Fluid from the third portion 33c may be collected in one or more of the sample chambers 44a and 44b. Further, the sample chambers 44a and 44b may be interconnected with flowlines that extend to other sample chambers 44, other portions of the downhole tool 10, the borehole and/or other charging chambers.
As shown, sample cavity 48a of sample chamber 44a is fluidly connected to the conduit system 33. Valve 46 selectively permits fluid to pass from the conduit system into the sample cavity. As fluid enters sample cavity 48a through an inlet port 54a, buffer fluid in buffer cavity 50a applies pressure to the piston. The pressure in the buffer cavity is preferably adapted to permit fluid to gradually enter sample cavity 48a in a manner that retains the quality of the sample.
As shown, sample cavity 48b of sample chamber 44b is fluidly connected to the conduit system 33 via a series of conduits. Valve 47 selectively permits fluid to pass from the flowline 33c into sample chamber conduit 58a. Sample chamber conduit 58a is fluidly connected to sample cavity 44b via conduit 57b. As fluid enters sample cavity 48b through an inlet port 54b, buffer fluid in buffer cavity 50b applies pressure to the piston. The pressure in the buffer cavity is preferably adapted to permit fluid to gradually enter sample cavity 48b in a manner that retains the quality of the sample.
The buffer cavity 50a is fluidly connected to pressure compensator 35 via a series of conduits. Conduit 57a fluidly connects the buffer cavity 50a to a sample chamber conduit 58b. A first flowline 78a of pressure conduit 78 fluidly connects the sample chamber conduit 58b to the pressure compensator 35. A second flowline 78b of pressure conduit 78 fluidly connects the sample chamber conduit 58b to buffer cavity 50b. In this manner, pressure may be balanced between buffer cavity 50a, buffer cavity 50b and pressure compensator 35.
The buffer cavity 50b is fluidly connected to pressure compensator 35 via second flowline 78b of pressure conduit 78. Second flowline 78b of pressure conduit 78 fluidly connects the buffer cavity 50b to sample chamber conduit 58b. In this manner pressure may be balanced between buffer cavity 50b, buffer cavity 50a and pressure compensator 35.
The sampling system is preferably provided with pressure compensator 35 for applying a pressure or force to the sample chamber(s). The pressure compensator may be used to control the flow of fluid into the sample chamber(s) 44. The pressure compensator may also be used to compensate for the pressure or force experienced from the formation pressure while sampling. The pressure compensator may be used in place of, or in combination with, a pump. The pressure compensator may be used to maintain sample integrity and/or to manipulate fluid flow trough the flowlines. In some cases, the pressure compensator may be selectively activated to control the fluid flow. In other cases, the pressure compensator may be configured to perform without selective activation.
The pressure compensator 35 has a stationary piston 66 and a movable piston 70 therein defining a first cavity 62, a second cavity 72 and a third cavity 84. The movable piston separates and defines the first cavity 62 and the second cavity 72 positioned within pressure compensation chamber 35 and above stationary piston 66. Third cavity 84 is defined by the portion of the pressure compensation chamber 35 below stationary piston 66.
Movable piston 70 slidably moves within pressure compensation chamber 35 to separate first cavity 62 from second cavity 72 and define the corresponding volumes therein. Stationary piston 66 separates variable volume second cavity 72 from third fixed volume cavity 84. A fourth variable volume cavity 64 is located within stationary piston 66. Rod 71 of movable piston 70 extends into and slidably moves within stationary piston 66 to define fourth variable volume 64.
Fluid in first cavity 62 is fluidly connected via flowline 78 to buffer cavities 50a, 50b. The fluid in second cavity 72 is in fluid communication with the wellbore via flowline 81. Pressure in third cavity 84 is in fluid communication with fluid in fourth chamber 64 via flowline 86. Valves, such as valves 82 and 88, may be positioned in the flowlines to permit selective fluid communication. In other cases, such valves may be omitted to allow the system to operate without the requirement of actuating valves. In some cases, such valves may be check, throttle or other valves to manipulate flow. Additional flowline devices, such as restrictors, or other fluid manipulators may also be used.
In operation, fluid is admitted into the sample cavities 48a, 48b through fluid conduit system 33. Fluid may be selectively diverted by activating valves 46 and 47. As fluid flows into the sample cavities, the pistons 52a, 52b are displaced in response to the change in pressure resulting therefrom. A pressure differential exists between the pressure of the formation fluid in the sample cavities and the pressure provided by the pressure compensator. Typically, the pressure compensator applies a pressure to the buffer cavities to oppose the formation fluid pressure in the sample cavities. Thus, the movable pistons adjust to the opposing pressures in the sample chambers, typically until equilibrium is reached.
The differential pressure provided by the pressure compensator is typically generated by the wellbore or hydrostatic pressure in wellbore cavity 72. In one mode, the flowline 81 may be valveless and wellbore cavity 72 may be open to the wellbore so that it may equalize to the hydrostatic pressure therein. The pressure in wellbore cavity 72 applies a force to piston 70. As a result, cavities 62, 50a and 50b adjust to the pressure in the wellbore cavity. At the same time, formation pressure in cavities 48a, 48b applies pressure to buffer cavities 50a, 50b. Thus, the pressure in the cavities adjusts until equilibrium is achieved therebetween. Desirably, the pressure compensator permits formation fluid to flow gradually into chambers 48a, 48b to prevent damage thereto. While additional valving, flowlines and pumps may optionally be used, this type of pressure manipulation eliminates the requirement to add such features to draw fluid into the tool and/or manipulate fluid flow and/or pressures.
In another mode, the flowline 81 may be provided with a valve 82 to permit selective fluid communication between wellbore cavity 72 and the wellbore. In this manner, pressure in wellbore cavity 72 may be manipulated to control the force applied to piston 70. As a result, cavities 62, 50a and 50b may be selectively adjusted to the pressure in the wellbore cavity. At the same time, formation pressure in cavities 48a, 48b applies pressure to buffer cavities 50a, 50b. Thus, the pressure in the cavities may be selectively adjusted until equilibrium is achieved therebetween. Preferably, the pressure compensator is manipulated to permit formation fluid to flow as desired into chambers 48a, 48b. A valve 88 may also be provided in flowline 86 to selectively bleed off any excess pressure in the pressure compensator to chamber 84. In this manner, the flow of fluid into the chambers and the pressures contained in certain cavities may be manipulated. Pressure balancing may be selectively achieved for one or more of the cavities.
The pressure compensator 35 is preferably a device fluidly connected to one or more sample chambers for applying a pressure or force to compensate for the pressure or force experienced from the formation pressure. While FIG. 3A depicts one pressure compensator 35, it will be appreciated by one of skill in the art that a variety of one or more pressure compensators may be used with one or more sample chambers in a variety of locations throughout the downhole tool.
The pressure compensator may be a piston or other device capable of balancing the pressures in the chamber. The pressure compensator may be used to create a pressure differential in the chambers to induce formation fluid to flow into the sample cavities. In some high temperature applications, pumps may fail. Thus, it is sometimes desirable to provide a pressure compensator to create the pressure differential to drive fluid into the tool. The pressure compensator can be a passive device that does not require a power supply. Rather, the pressure compensator can obtain its energy from the pressure differential between at least two different pressure sources, such as from the formation and an internal pressure chamber. However, in some cases, it may be desirable to provide an active pressure compensator device.
While FIG. 3A depicts two sample chambers 44a and 44b for collecting samples for simplicity, it will be appreciated by one of skill in the art that a variety of one or more identical or different sample chambers may be used. Further, while the sample chambers 44a and 44b are depicted in FIG. 3A as being identical and positioned serially, one or more sample chambers 44 can be positioned in series and/or parallel.
Referring now to FIG. 3B, an alternate fluid sampling system 34a of downhole tool 10 is depicted. The sample system 34a includes a sample chamber 102 and a dump chamber 104. Preferably, the sample chamber 102 is interconnected in parallel with the dump chamber 104. A pressure chamber 110 is also preferably provided to apply a pressure to the sample and/or dump chambers. However, alternate configurations of one or more various sized sample, dump and/or pressure chambers positioned in series and/or parallel in various portions of the downhole tool may be used.
The sampling system 34a may be used in the downhole tool in addition to, or in place of the sampling system 34 of FIG. 3A. The sampling system may be positioned in one or more modules in various locations about the downhole tool. Flowline 136 may be operatively connected to the probe and/or existing flowlines, such as one or more of the flowlines of conduit system 33 (FIG. 2).
The sample chamber 102 and the dump chamber 104 can be constructed in a variety of manners. For example, the sample chamber 102 can be constructed in a similar manner as the sample chambers 44A and 44B shown in FIG. 3A. Also, one or more of the sample chambers can function as one or more dump chambers 104. Further examples of sample chambers, dump chambers and/or related configurations may be seen in U.S. Pat. Nos. 3,859,851; 6,467,544; 6,659,177; 6,688,390; 6,769,487; 2003/042021; and 2005/0150287.
A flowline 136 fluidly connects the probe through the downhole tool to the sample chamber 102 and the dump chamber 104. A first flowline 136a fluidly connects flowline 136 to the sample chamber 102. A second flowline 136b fluidly connects flowline 136 to the dump chamber 104. Valve 108 selectively diverts fluid from flowline 136 to first and second flowlines 136a, 136b. Typically, the dump chamber 104 is filled before the sample chamber 102 to remove contamination. After a certain amount of fluid enters the dump chamber, or when the fluid is determined to be clean, fluid may be diverted into the sample chamber 102.
Sample chamber 102 and dump chamber 104 are operatively connected to pressure chamber 110 via flowline 112. A first flowline 112a extends from flowline 112 to sample chamber 102. A second flowline 112b extends from flowline 112 to dump chamber 104. Valve 116 is provided to permit selective fluid communication with the pressure chamber 110 to apply pressure thereto.
The pressure chamber 110 may be a chamber with gas, such as an atmospheric chamber. The pressure chamber 110 may also be constructed in a similar manner as the pressure compensator 35 shown in FIG. 3A. The chambers of FIGS. 3A and 3B may be used interchangeably as desired to achieve the desired sample and/or pressures.
Referring now to FIG. 4, the electronics module 30 of FIGS. 1 and 2 is shown in greater detail. The electronics module 30 includes electronics 37 and a cooling system 39. Cooling system 39 includes a cooling driver 39a and a cooling flow unit 39b. The cooling drive 39a preferably includes a Stirling cooler, such as the one described in co-pending U.S. Patent Application No. 2005/0097911, assigned to the assignee of the present application.
As shown, the cooling driver 39a is a Stirling cooler that operates in cooperation with the cooling flow unit 39b. The Stirling cooler is preferably positioned adjacent the cooling flow unit 39b for magnetic cooperation therebetween.
The cooling flow unit 39b is operatively connected to the electronics 37 for passing a cooling fluid therethrough. Most or all of the electronics of the downhole tool are preferably consolidated into a location adjacent to the cooling flow unit 39b and/or components thereof for more efficient operation. However, one or more cooling systems may be positioned at various locations about the tool to provide cooling where needed. Cooling flowlines may also be positioned throughout the tool to pass cooling fluid near heat bearing objects to remove and/or dissipate heat therefrom.
The Stirling cooler 39a includes two pistons 142, 144 disposed in cylinder 146. The cylinder 146 is filled with a working gas, typically air, helium or hydrogen at a pressure of several times (e.g., 20 times) the atmospheric pressure. The piston 142 is coupled to a permanent magnet 145 that is in proximity to an electromagnet 148 fixed on the housing. When the electromagnet 148 is energized, its magnetic field interacts with that of the permanent magnet 145 to cause linear reciprocating motion of piston 142. Thus, the permanent magnet 145 and the electromagnet 148 form a moving magnet linear motor.
The particular sizes and shapes of the magnets shown are for illustration only and are not intended to limit the scope of the invention. One skilled in the art will also appreciate that the locations of the electromagnet and the permanent magnet may be reversed, i.e., the electromagnet may be fixed to the piston and the permanent magnet fixed on the housing (not shown).
The electromagnet 148 and the permanent magnet 145 may be made of any suitable materials. The windings and lamination of the electromagnet are preferably selected to sustain high temperatures (e.g., up to 260.degree. C.). In some embodiments, the permanent magnets of the linear motors are made of a samarium-cobalt (Sm—Co) alloy to provide good performance at high temperatures. The electricity required for the operation of the electromagnet may be supplied from the surface, from conventional batteries in the downhole tool, from generators downhole, or from any other means known in the art.
The movement of piston 142 causes the gas volume of cylinder 146 to vary. Piston 144 can move in cylinder 146 like a displacer in the kinematic type Stirling engines. The movement of piston 144 is triggered by a pressure differential across both sides of piston 144. The pressure differential results from the movement of piston 142. The movement of piston 144 in cylinder 146 moves the working gas from the downhole of piston 144 to the uphole of piston 144, and vice-versa. This movement of gas coupled with the compression and decompression processes results in the transfer of heat from object 147 to heat dissipating device 143. As a result, the temperature of the object 147 decreases. The Stirling cooler 39 may include a spring mass 141 to help reduce vibrations of the cooler resulting from the movements of the pistons and the magnet motor.
The Stirling cooler 39 in FIG. 4 may be used to cool object 147. The Stirling cooler is also adapted to drive the cooling flow unit 39b. In particular, the reciprocating action of the Stirling cooler may be magnetically coupled to and drive a cooling pump 149 to cool the electronics 37. A magnet 153 is coupled to piston 144 to magnetically drive the cooling pump 149. The cooling pump 149 includes an electronics piston 150 having a permanent magnet 151 attached thereto. The piston 150 and attached magnet 151 are positioned in a pump chamber 152 and magnetically driven by reciprocating magnet 153. The pump chamber 152 is preferably positioned adjacent the Stirling cooler for operative cooperation therewith.
The electronics magnet 150 is slidably positioned in the pump chamber 152 and reciprocates therein in response to the magnetic field created by the Stirling cooler. The reciprocating electronics magnet pumps cooling fluid through a cooling flowline 154 positioned near the electronics. The cooling flowline 154 preferably forms a closed loop that passes through the electronics 37, or a chassis supporting the electronics, to dissipate heat therefrom. One or more cooling flowlines in a variety of configurations may be positioned throughout various portions of the tool to cool such portions as desired.
The electronics are preferably mounted on a chassis, electronics housing or other mounting means to support the electronics in the Dewar flask. The electronics chassis is preferably made of a material of high thermal mass or high thermal conductivity, such as copper, to serve as a heat sink. This heat sink may be used in combination with the cooling system to dissipate heat. Additionally, should the cooling system fail, or not be in use, the heat sink may be used to absorb and/or spread the heat.
While FIG. 4 shows a Stirling cooler 39a having a magnet motor that uses electricity to power the Stirling cooler, one skilled in the art will appreciate that other energy sources (or energizing mechanisms) may also be used. For example, operation of the Stirling cooler (e.g., the back and forth movements of piston 142 in FIG. 4) may be implemented by mechanical means, such as a fluid-powered system that uses the energy in the mud flow coupled to a valve system and/or a spring (not shown).
In cases where drilling tools are used, the hydraulic pressure of mud flowing through the drilling tool could be used to push the electronics magnet, or piston, in one direction, while a spring is used to move the piston in the other direction. A conventional valve system is used to control the flow of mud to the Stirling piston in an intermittent fashion. Thus the coordinated action of a hydraulic system, a spring, and a valve system results in a back and forth movement of the piston 142. A corresponding pumping mechanism may then be used in place of the cooling pump 149. The pumps can be powered by a cooler power network or using independent power means.
The electronics module can be any device capable of housing or supporting electronics disposed therein. While some electronics may be dispersed throughout the tool, the electronics are preferably consolidated into a single portion of the tool, or a single module. These electronics may include, for example, sources, sensors or other heat sensitive parts that need to function in a harsh downhole environment. Preferably, the electronics are mounted on the electronics chassis and supported within the electronics module.
Preferably, the electronics module 30 is provided with an insulated housing 124, such as a Dewar flask, adapted to thermally isolate the electronics contained therein. The housing 124 is preferably adapted to support, protect and insulate the electronics 37 and, if desired, at least a portion of the Stirling cooler 39. Also, the housing 124 can be provided with additional thermal layer or barriers to further insulate the electronics contained therein. Preferably, the insulated housing is sufficient to provide a heat barrier between the electronics module and the probe, and/or sampling modules.
Preferably, the electronics disposed in the electronics module 30 includes one or more gauges 128, such as a quartz gauge, strain gauge or other sensor(s). A flowline 33b of the conduit system 33 extends from the probe 32 to the electronics module 30. Preferably, the fluid in the flowline is fluidly connected to gauge 128 so that characteristics of the fluid in the flowline may be measured. A buffer fluid is preferably positioned in the flowline 33b to act as a buffer fluid between the formation fluid and the gauge. Such a buffer fluid may be used to prevent contamination of the flowline and/or gauge(s).
Gauge 128 depicts an example of a gauge or sensor positionable with the electronics. The gauge 128 is supported by the electronics chassis and positioned adjacent cooling flowline 154 so that heat may be carried away by the coolant passing through the cooling flowline.
Gauge 128 is preferably a pressure sensor, such as a pressure gauge or the like, which is capable of measuring or monitoring the formation pressure based on the pressure of the formation fluid entering the probe 32. However, the gauge 128 can be any type of device adapted to sense or measure other properties and characteristics of the formation fluid entering the probe, such as density, resistivity and/or contamination levels. One or more of various types of gauges may be placed in the electronics module as desired. Also, one or more sensors may be disposed at various locations throughout the downhole toot (ie. along the flowlines and/or chambers to enable monitoring of the downhole fluids). These sensors may be sensors, gauges, monitors or other devices capable of measuring properties of the fluids and/or downhole conditions, such as density, resistivity or pressure. The data collected in the tool may be transmitted to the surface and/or used for downhole decision making.
Appropriate computer devices, processing equipment and/or other electronics may be provided to achieve these capabilities or other functions. For example, a processor (not shown) may be used to collect, analyze, assemble, communicate, respond to and/or otherwise process downhole data. The downhole tool may be adapted to perform commands in response to the processor equipment, such as activating valves. These commands may be used to perform downhole operations.
The downhole tool can be provided with other means for assisting the formation evaluation process. For example, a clean-up operation may be carried out prior to capturing a sample in at least one sample chamber wherein a portion of the formation fluid is directed to a borehole exit (not shown) before the formation fluid is allowed to enter the at least one sample chamber Formation fluid may be directed to the borehole exit port (not shown) until it is determined that the formation fluid flowing from the formation is substantially free of contaminants and debris. Furthermore, the downhole tool can be provided with additional filters or other components to selectively remove a contaminated portion of the formation fluid from the sample chamber, such as described in U.S. Patent Application No. 2005/0082059.
It will be understood from the foregoing description that various modifications and changes may be made in the preferred and alternative embodiments of the present invention without departing from its true spirit. For example, embodiments of the invention may be easily adapted and used to perform specific formation sampling or testing operations without departing from the scope of the invention as described herein.
This description is intended for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. “A,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded.

## Claims

1. A formation evaluation tool positionable in a wellbore penetrating a subterranean formation, comprising:
an electronics module comprising:
a first cooler comprising:
a cylinder filled with a pressurized working gas;
a magnetically driven piston positioned in the cylinder;
a gas driven piston positioned in the cylinder such that reciprocation of the magnetically driven piston causes reciprocation of the gas driven cylinder; and
a first magnet coupled to the gas driven piston; and

a second cooler comprising:
a cooling flow line extending through electronics and forming a closed loop with a pump chamber;
an electronics piston positioned in the pump chamber; and
a second magnet coupled to the electronics piston within the pump chamber such that the second magnet and the electronics piston reciprocate within the pump chamber in response to reciprocation of the first magnet coupled to the gas driven piston of the first cooler, thereby pumping cooling fluid within the cooling flow line.

2. The formation evaluation tool of claim 1 wherein at least one of the first and second magnets comprises a samarium-cobalt alloy.

3. The formation evaluation tool of claim 1 wherein the first cooler comprises a spring mass configured to reduce vibrations resulting from movement of the magnetically driven piston and the gas driven piston.

4. The formation evaluation tool of claim 1 wherein the electronics are mounted on a chassis comprising a heat sink.

5. The formation evaluation tool of claim 1 wherein the electronics module comprises an insulated housing surrounding the electronics and the second cooler.

6. The formation evaluation tool of claim 5 wherein the housing surrounds at least a portion of the first cooler.

7. The formation evaluation tool of claim 1 wherein the electronics comprises a quartz gauge adjacent the cooling flow line.

8. The formation evaluation tool of claim 1 wherein the electronics comprises a strain gauge adjacent the cooling flow line.

9. The formation evaluation tool of claim 1 wherein the electronics comprises a pressure sensor adjacent the cooling flow line.

10. A subterranean formation evaluation tool, comprising:
an electronics module comprising:
electronics;
a Stirling cooler comprising:
first and second pistons disposed in a cylinder that is filled with a pressurized working gas;
an electromagnet;
a first permanent magnet coupled to the first piston in proximity to the electromagnet such that energizing the electromagnet causes linear reciprocating motion of the first piston, wherein:
movement of the first piston causes the gas volume of the cylinder to vary;
movement of the second piston is triggered by a pressure differential across both sides of the second piston resulting from movement of first piston; and
movement of the second piston in the cylinder moves the working gas from downhole of the second piston to uphole of the second piston, and vice-versa; and

a magnet coupled to the second piston; and

a cooling system comprising:
a pump chamber;
a cooling flow line forming a closed loop extending from the pump chamber, through the electronics, and returning to the pump chamber;
an electronics piston positioned in the pump chamber; and
a second permanent magnet coupled to the electronics piston within the pump chamber such that the second permanent magnet and the electronics piston reciprocate within the pump chamber in response to reciprocation of the magnet coupled to the second piston of the Stirling cooler, thereby pumping cooling fluid within the cooling flow line.

11. The subterranean formation evaluation tool of claim 10 wherein the permanent magnet comprises a samarium-cobalt alloy.

12. The subterranean formation evaluation tool of claim 10 wherein the Stirling cooler comprises a spring mass configured to reduce vibrations of the Stirling cooler resulting from movement of the first and second pistons and permanent magnet.

13. The subterranean formation evaluation tool of claim 10 wherein the electronics are mounted on a chassis comprising a heat sink.

14. The subterranean formation evaluation tool of claim 10 wherein the electronics module comprises an insulated housing surrounding the electronics and the cooling system.

15. The subterranean formation evaluation tool of claim 14 wherein the housing surrounds at least a portion of the Stirling cooler.

16. The subterranean formation evaluation tool of claim 10 wherein the electronics comprises a quartz gauge adjacent the cooling flow line.

17. The subterranean formation evaluation tool of claim 10 wherein the electronics comprises a strain gauge adjacent the cooling flow line.

18. The subterranean formation evaluation tool of claim 10 wherein the electronics comprises a pressure sensor adjacent the cooling flow line.