Patent Publication Number: US-2023145431-A1

Title: Spoolable device, method for making a spoolable device, and system

Description:
BACKGROUND 
     In the resource recovery and fluid sequestration industries, there is need for signal conduction, sensory, and actuation operations in a downhole environment. One of the operational interests for such activity is the ability to spool a conductor that includes modules for various purposes. The art has struggled with spooling modules that inevitably are relatively long and relatively rigid. Such constructions inherently do not spool well. The art would therefore well receive alternatives that improve spoolability of modules that are needed in the downhole environment. 
     SUMMARY 
     An embodiment of a spoolable device including a first communication interface, a second communication interface, a power management module, a functional electrical module, and a junction joining each of the above elements together and creating a shared pressure chamber. 
     An embodiment of a method for making a spoolable device comprising welding a functional electrical module to a first portion of a junction box, welding a first communication interface to the first portion of a junction box, welding a power management module to a second portion of a junction box, welding a second communication interface to the second portion of a junction box, and welding the first portion of a junction box to the second portion of the junction box to form a pressure chamber inside the first and second portions of the junction box. 
     A borehole system including a borehole in a subsurface formation, a string in the borehole, and a device disposed within or as a part of the string. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG.  1    is a schematic view of a spoolable device as disclosed herein; 
         FIGS.  2 - 9    illustrate a sequence related to the making of the spoolable device; and 
         FIG.  10    is a schematic view of a borehole system employing the spoolable device as disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     Referring to  FIG.  1   , a spoolable device  10  is illustrated. The device  10  includes an uphole communications interface  12 , a downhole communications interface  14 , a power management module  16 , and a functional electrical module  18  (e.g., a sensor, actuator, splice module, etc.). Each of the components  12 ,  14 ,  16 ,  18  are joined together via a junction box (made up of two junction box halves  30  and  42 ) that becomes a pressure housing for all of the components. Individual pressure housings are omitted in the construction as disclosed and length and girth of the device  10  are reduced relative to existing prior art devices of similar function. Because the components effectively share the same space at a junction thereof, the device  10  is robust and yet of smaller form factor. As will be appreciated by one of ordinary skill in the art, a smaller form factor is highly advantageous for a spoolable device since the device when spooled will define a tangent to the spool and the conductors entering and exiting the device will need to experience relatively larger bending angles to come back to the spool. The shorter a device is, the less the angularity for the conductor while spooled. Lesser angularity at ends of the connector reduces failures of the spool and increases spooling density, which reduces footprint, both of which are clearly beneficial to the art. The device  10  is welded together even while sensitive electronics are present inside. 
     The device  10  is made in the following sequence. Referring to  FIGS.  2 - 9   , the functional electrical module is constructed by rotary welding an adapter  20  to one end  22  of a function element  24 , which may be a transducer, other type of sensor, actuator, etc. At a second end  26  of the element  24 , another rotary weld is placed to join the element  24  with a junction box adapter  28 . In  FIG.  3   , the components of  FIG.  2   , through junction box adapter  28 , are joined with a junction box  30 , again, in an embodiment, by rotary welding. Referring to  FIGS.  3  and  4    simultaneously one half of the device  10  is completed by welding a feedthrough  32  of communications interface  14  to a junction box adapter  34  at joint  36  by, for example, rotary welding. Once the adapter  34  is welded to the feedthrough  32 , the interface  14  may be joined to the junction box  30 , by, for example, rotary welding. The condition of the build at this point is seen in  FIG.  5    where it is also illustrated that a face welding operation is undertaken to weld the adapter  34  to the junction box  30 . 
     Following the foregoing, another half of the device  10  is constructed in a similar manner. A junction box adapter  40  that will be a part of the interface  12  is welded to junction box  42  in another rotary process for example. A junction box adapter  44  is welded to a cable head  46  in  FIG.  7    to create interface  12 , which is then rotary welded to junction box  42 . In this condition, referring to  FIG.  8   , the junction box adapter  44  is face welded to the junction box  42 . Referring to  FIG.  9   , two subassemblies  50  and  52  are joined together including internal electronics extending through the junction and then rotary welded to form the device  10  illustrated in  FIG.  1   . As completed, the device  10  is a pressure vessel in one piece not requiring individual seals but rather sharing the pressure chamber produced. 
     Various welding processes mentioned herein include rotary welding or face welding and may employ an electron beam process, a laser weld process or other fusing process that is capable of controlling heat affected zone such that internal electronic components are not damaged. Further, it is contemplated that all description of “welding” may be substituted, in embodiments, by alternate means of bonding, whether chemical or mechanical providing a pressure vessel is created and electronics therein are not damaged. In such a way, the benefit of this disclosure, superior spoolability, may still be reaped. Further, it is to be appreciated that while only one device  10  is illustrated, more than one is contemplated on a conductor. Signals being borne by a conductor may be passed through one or more devices  10 . A plurality of devices  10  may be disposed along a conductor evenly or unevenly as is desired and practicable for the end purpose of each device  10 . For example, perhaps one device  10  will connect to a first type of actuator for a packer for example, while a second device  10  might connect to a valve, etc. 
     Referring to  FIG.  10   , a borehole system  60  is illustrated. The system  60  comprises a borehole  62  in a subsurface formation  64 . A string  66  is disposed in the borehole  62  and a device  10  is disposed within or as a part of the string  66 . 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1: A spoolable device including a first communication interface, a second communication interface, a power management module, a functional electrical module, and a junction joining each of the above elements together and creating a shared pressure chamber. 
     Embodiment 2: The device as in any prior embodiment wherein the functional electrical element is a sensor. 
     Embodiment 3: The device as in any prior embodiment wherein the functional electrical element is an actuator. 
     Embodiment 4: A method for making a spoolable device comprising welding a functional electrical module to a first portion of a junction box, welding a first communication interface to the first portion of a junction box, welding a power management module to a second portion of a junction box, welding a second communication interface to the second portion of a junction box, and welding the first portion of a junction box to the second portion of the junction box to form a pressure chamber inside the first and second portions of the junction box. 
     Embodiment 5: The method as in any prior embodiment wherein the welding the functional electrical module to the first portion of the junction box further includes welding an adapter to the element at one end of the element and welding a junction box adapter to an opposite end of the element. 
     Embodiment 6: The method as in any prior embodiment wherein the welding the first or second communication interface includes welding a junction box adapter to a feedthrough. 
     Embodiment 7: The method as in any prior embodiment wherein the welding includes rotary welding. 
     Embodiment 8: The method as in any prior embodiment wherein the welding further includes face welding. 
     Embodiment 9: The method as in any prior embodiment wherein the welding is electron beam welding. 
     Embodiment 10: A borehole system including a borehole in a subsurface formation, a string in the borehole, and a device as in any prior embodiment disposed within or as a part of the string. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” and/or “generally” can include a range of ±8% or 5%, or 2% of a given value. 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.