Patent Publication Number: US-2022228448-A1

Title: Molded composite inner liner for metallic sleeves

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. application Ser. No. 16/400,573 entitled “Molded Composite Inner Liner for Metallic Sleeves,” filed on May 1, 2019, which claims priority from U.S. Provisional Application Ser. No. 62/683,803 entitled “Molded Composite Inner Liner for Metallic Sleeves,” filed on Jun. 12, 2018, the entire disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     The present disclosure relates generally to wellbore operations and, more particularly, to a sleeve assembly for a downhole logging tool. 
     During drilling operations for the extraction of hydrocarbons, a variety of recording and transmission techniques are used to provide or record data downhole, for example, from the vicinity of a drill bit. Measurements of the surrounding subterranean formations may be made throughout drilling operations using downhole measurement and logging tools, such as measurement-while-drilling (MWD) and/or logging-while-drilling (LWD) tools, which help characterize the formations and aid in making operational decisions. Wellbore logging tools make measurements that may be used to determine the electrical resistivity (or its inverse, conductivity) of the formations being penetrated, where the electrical resistivity indicates various features of the formations. Those measurements may be taken using one or more antennas coupled to, within or otherwise associated with the wellbore logging tools. 
     Logging tool antennas are often formed by positioning coil windings about an axial section of the logging tool, such as a drill collar. A ferrite material or “ferrites” are sometimes positioned beneath the coil windings to increase the efficiency and/or sensitivity of the antenna. 
     The ferrites facilitate a higher magnetic permeability path (for example, a flux conduit) for the magnetic field generated by the coil windings, and help shield the coil windings from the drill collar and associated losses (for example, eddy currents generated on the drill collar). The antenna must be protected from the harsh downhole environment. Generally, the antennas are protected by positioning a sleeve around the antennas to protect the antennas from abrasion and erosion while the downhole logging tool traverses the wellbore. As the sleeve interferes with the operation of the antennas, slots are formed in the sleeve to provide a dipole angle for the electromagnetic field of the antennas to penetrate the formation or object of interest. However, debris, fluids or other harmful materials could penetrate the slots and damage the antennas. Typically, a non-conductive inner sleeve is inserted into the outer sleeve to cover the slots and protect the antennas or the slots could be filled with an epoxy. Both solutions still allowed for some erosion and exposure of the antennas to the downhole environment. Both solutions increase costs, wear and tear and decrease reliability. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications alterations combinations, and equivalents in form and function, without departing from the scope of this disclosure. 
         FIG. 1  s a schematic diagram of an exemplary drilling system, according to one or more aspects of the present disclosure. 
         FIG. 2  is a schematic diagram of an exemplary wireline system, according to one or more aspects of the present disclosure. 
         FIG. 3A  is a partial isometric view of an exemplary portion of a wellbore logging tool, according to one or more aspects of the present disclosure. 
         FIG. 3B  is a cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 4  is a top cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 5  is an isometric view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 6  is a partial cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 7  is a partial cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 8  is a partial cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 9  is a partial cross-sectional view of a sleeve assembly, according to one or more aspects of the present disclosure. 
         FIG. 10  is a flowchart of logging operation, according to one or more aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates generally to wellbore operations and, more particularly, to a protective sleeve assembly for antennas of a wellbore logging tools used in hydrocarbon drilling operations. 
     Downhole environments may have harsh operating conditions such as abrasive and erosive fluids including liquids, solid particles, and other debris. During downhole logging operations, for example, measurement while drilling (MWD) and logging while drilling (LWD) operations, a downhole tool that includes an antenna may include sections that include an antenna for receiving data related to a formation of interest or any other object. These antennas are susceptible to damage and catastrophic failure due to the harsh downhole operating conditions. Thus, these antennas must be protected while at the same time provided with the ability to obtain the desired measurements or data. 
     The antenna may be protected by an outer sleeve. To provide adequate protection from the downhole operating conditions, the outer sleeve is generally constructed using a metallic material that interferes with the operation of the antenna. To provide for proper operation of the antenna, the outer sleeve comprises one or more slots that allow the antenna to transmit and receive signals to and from the downhole tool. However, the slots allow for erosion and abrasion, for example, from a downhole fluid. Typically, a non-conductive inner sleeve is inserted or press-fit into the outer sleeve to provide protection for the antenna and the slots are filled with a non-conductive material. Filling the slots with a non-conductive material protects the antenna from the downhole operating conditions but may not be adequate as the non-conductive material is also susceptible to erosion and abrasion and typically does not bind sufficiently to the inner sleeve. For example, the non-conductive material may comprise an epoxy that breaks, cracks or otherwise weakens during a downhole operation which reduces the life of the outer sleeve, the inner sleeve, the antenna or any combination thereof and requires expensive and time-consuming repair or replacement. Further, the inner sleeve necessarily reduces the available space within the outer sleeve for the antenna and necessary corresponding components. Insertion of the inner sleeve also creates a gap between the inner sleeve and the outer sleeve. Repairing the outer sleeve and the inner sleeve with the epoxy filled slots may be time-consuming, expensive and laborious and may result in delays for completing the downhole operation. 
     According to one or more embodiments, a composite insert may be disposed or positioned within the slot that provides sufficient boding to the outer sleeve to protect the internal components of the outer sleeve, such as the antenna. A composite insert does not have gaps between the outer sleeve and the insert and is not as susceptible to the downhole operating conditions as the previously used non-conductive material that was injected into the slots. The composite insert provides a reliable and cost-efficient protection for the components of the outer sleeve. 
       FIG. 1  is a schematic diagram of an exemplary drilling system  100  that may employ the principles of the present disclosure, according to one or more embodiments. As illustrated, the drilling system  100  may include a drilling platform  102  positioned at the surface and a wellbore  104  that extends from the drilling platform  102  into one or more subterranean formations  106 . In other embodiments, such as in an offshore drilling operation, a volume of water may separate the drilling platform  102  and the wellbore  104 . Even though  FIG. 1  depicts a land-based drilling platform  102 , it will be appreciated that the embodiments of the present disclosure are equally well suited for use in other types of drilling platforms, such as offshore platforms, or rigs used in any other geographical locations. The present disclosure contemplates that wellbore  104  may be vertical, horizontal or at any deviation. 
     The drilling system  100  may include a derrick  108  supported by the drilling platform  102  and having a traveling block  110  for raising and lowering a drill string  112 . A kelly  114  may support the drill string  112  as it is lowered through a rotary table  116 . A drill bit  118  may be coupled to the drill string  112  and driven by a downhole motor and/or by rotation of the drill string  112  by the rotary table  116 . As the drill bit  118  rotates, it creates the wellbore  104 , which penetrates the subterranean formations  106 . A pump  120  may circulate drilling fluid through a feed pipe  122  and the kelly  114 , downhole through the interior of drill string  112 , through orifices in the drill bit  118 , back to the surface via the annulus defined around drill string  112 , and into a retention pit  124 . The drilling fluid cools the drill bit  118  during operation and transports cuttings from the wellbore  104  into the retention pit  124 . 
     The drilling system  100  may further include a bottom hole assembly (BHA) coupled to the drill string  112  near the drill bit  118 . The BHA may comprise various downhole measurement tools such as, but not limited to, measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools, which may be configured to take downhole measurements of drilling conditions. The MWD and LWD tools may include at least one wellbore logging tool  126 , which may comprise one or more antennas capable of receiving and/or transmitting one or more electromagnetic (EM) signals that are axially spaced along the length of the wellbore logging tool  126 . The one or more antennas are protected by a protective sleeve assembly as discussed below with respect to  FIGS. 3A, 3B, 4, 5, 6, 7, 8 . As will be described in detail below, the wellbore logging tool  126  may further comprise a plurality of ferrites used to shield the EM signals and thereby increase the azimuthal sensitivity of the wellbore logging tool  126 . 
     As the drill bit  118  extends the wellbore  104  through the formations  106 , the wellbore logging tool  126  may continuously or intermittently collect azimuthally-sensitive measurements relating to the resistivity of the formations  106 , for example, how strongly the formations  106  opposes a flow of electric current. The wellbore logging tool  126  and other sensors of the MWD and LWD tools may be communicably coupled to a telemetry module  128  used to transfer measurements and signals from the BHA to a surface receiver (not shown) and/or to receive commands from the surface receiver. The telemetry module  128  may encompass any known means of downhole communication including, but not limited to, a mud pulse telemetry system, an acoustic telemetry system, a wired communications system, a wireless communications system, or any combination thereof. In certain embodiments, some or all of the measurements taken at the wellbore logging tool  126  may also be stored within the wellbore logging tool  126  or the telemetry module  128  for later retrieval at the surface upon retracting the drill string  112 . 
     At various times during the drilling process, the drill string  112  may be removed from the wellbore  104 , as shown in  FIG. 2 , to conduct measurement/logging operations. More particularly,  FIG. 2  depicts a schematic diagram of an exemplary wireline system  200  that may employ the principles of the present disclosure, according to one or more embodiments. Like numerals used in  FIGS. 1 and 2  refer to the same components or elements and, therefore, may not be described again in detail. As illustrated, the wireline system  200  may include a wireline instrument sonde  202  that may be suspended into the wellbore  104  by a cable  204 . The wireline instrument sonde  202  may include the wellbore logging tool  126  described above, which may be communicably coupled to the cable  204 . The cable  204  may include conductors for transporting power to the wireline instrument sonde  202  and also facilitate communication between the surface and the wireline instrument sonde  202 . A logging facility  206 , shown in  FIG. 2  as a truck, may collect measurements from the wellbore logging tool  126 , and may include computing and data acquisition systems  208  for controlling, processing, storing, and/or visualizing the measurements gathered by the wellbore logging tool  126 . The computing facilities  208  may be communicably coupled to the wellbore logging tool  126  by way of the cable  204 . 
       FIG. 3A  is a partial isometric view of an exemplary portion  300  of a wellbore logging tool  126 , according to one or more aspects of the present disclosure. The portion  300  is depicted as including an antenna assembly  302  that can be positioned about a tool mandrel  304 , such as a drill collar or the like and inserted, disposed or position in a sleeve assembly of the wellbore logging tool  126 . The antenna assembly  302  may include a bobbin  306  and a coil  308  wrapped about the bobbin  306  and extending axially by virtue of winding along at least a portion of an outer surface of the bobbin  306 . 
     The bobbin  306  may structurally comprise a high temperature plastic, a thermoplastic, a polymer (for example, polyimide), a ceramic, or an epoxy material, but could alternatively be made of a variety of other non-magnetic, electrically insulating/non-conductive materials. The bobbin  306  can be fabricated, for example, by additive manufacturing (for example, 3D printing), molding, injection molding, machining, or other known manufacturing processes. 
     The coil  308  can include any number of consecutive “turns” (for example, windings of the coil  308 ) about the bobbin  306 , but typically will include at least a plurality (for example, two or more) consecutive full turns, with each full turn extending 360 degrees about the bobbin  306 . In some embodiments, a pathway for receiving the coil  308  may be formed along the outer surface of the bobbin  306 . For example, one or more grooves may be defined in the outer surface of the bobbin  306  to receive and seat the coil  308 . In other embodiments, however, the outer surface of the bobbin  306  may be smooth or even. The coil  308  can be concentric or eccentric relative to a central axis  310  of the tool mandrel  304 . 
     As illustrated, the turns or windings of the coil  308  extend about the bobbin  306  at an angle  312  offset from the central axis  310 . As a result, the antenna assembly  302  may be characterized and otherwise referred to as an “antenna,” “tilted coil” or “directional” antenna. In the illustrated embodiment, the angle  312  is 45°, by way of example, and could alternatively be any angle offset from the central axis  310 , without departing from the scope of the disclosure. 
       FIG. 3B  is a cross-sectional view of a sleeve assembly  350 , according to one or more aspects of the present disclosure. A sleeve assembly  350  comprises a locking mechanism  360 , an outer sleeve  354 , one or more slots  358  and a non-conductive insert  356 . The outer sleeve  354  may comprise any material that includes properties that resist abrasion or erosion due to the downhole operating conditions. For example, the outer sleeve  354  may comprise a metallic material. Outer sleeve  354  comprises an annulus  352 . An antenna coil  308  or portion  300  as discussed above with respect to  FIG. 3A  may be positioned, disposed or inserted in the annulus  352  of sleeve assembly  350 . The locking mechanism  360  allows the sleeve assembly  350  to couple to one or more other assemblies, tools or portions of assemblies or tools. 
     The sleeve assembly  350  comprises one or more slots  358  distributed, formed, positioned or disposed about any one or more portions of the sleeve assembly  350 . In one or more embodiments, the sleeve assembly  350  may comprise one or more slots  358  distributed circumferentially at one or more angles as illustrated in the isometric view  500  of the sleeve assembly  350  of  FIG. 5 . The one or more slots  358  may be any width or length and may be at any angle, aligned axially with any axis, or at any other orientation or positioning. In one or embodiments, the slots may be of any dimension or shape including, but not limited to, rectangular, elongated, elliptical, key-shaped, spiraled, circular, or any other shape for dimension for any aperture or opening. In one or more embodiments, the one or more slots  358  may comprise straight edges, beveled edges, angled edges or any combination thereof. For example,  FIG. 8  illustrates a partial cross-sectional view of a sleeve assembly  350  with an outer sleeve  354  that comprises a slot  358 . The slot  358  comprises an angled edge  810  at an angle or deviation of  820  from a central axis of the outer sleeve  354 . For example,  FIG. 9  illustrates a partial cross-sectional view of a sleeve assembly  350  with an outer sleeve  354  that comprises a slot  358  with a beveled edge  910 . The slot  358  comprises a non-conductive insert  356  that provides insert retention at a top portion  920  and a bottom portion  930  of the slot  358 . The one or more slots  358  overlap with an antenna disposed in the annulus of the outer sleeve  354 . For example, an antenna is aligned or at least partially aligned with one or more slots  358  such that the slot allows the antenna, such as an antenna illustrated in  FIG. 3A , to function or operate as the one or more slots  358  allow the antenna to transmit or receive one or more signals to and from a formation of interest or any other object. 
     A non-conductive insert  356  may be disposed or positioned in any one or more of the one or more slots  358 . The non-conductive insert  356  may comprise a composite material. The non-conductive insert  358  comprises a material that does not substantially interfere with the functioning or operation of an antenna, for example, as illustrated in  FIG. 3A . The non-conductive insert  356  may be formed by any one or more processes including, but not limited to, molding, such as injection molding, subtracted machining, fusing, curing, bonding, masking, any other suitable process or procedure, or any combination thereof The non-conductive insert  356  adheres, bonds, cures, fuses, or otherwise affixes to the outer sleeve  354  such that no or only substantially inconsequential air gaps exists between the non-conductive insert  356  and the outer sleeve  354 . 
       FIG. 4  is a top cross-sectional view of a sleeve assembly, for example, sleeve assembly  350  of  FIG. 3B , according to one or more aspects of the present disclosure.  FIG. 4  illustrates one or more slots  358  disposed, positioned or otherwise distributed about an outer sleeve  354 . 
       FIG. 6  is a partial cross-sectional view of a sleeve assembly, for example, sleeve assembly  350 , according to one or more aspects of the present disclosure. An outer sleeve  354  may comprise a slot  358 . The slot  358  may be filled, packed, plugged or otherwise sealed with a non-conductive insert  356  such that non-conductive insert  356  forms bonds  610  with the outer sleeve  354  as discussed above. The seal formed by the non-conductive insert  356  prevents exposure of one or more components disposed or positioned in the annulus  352  of the outer sleeve  354  to erosive or abrasion materials or fluids. The bond  610  may be a chemical bond or a mechanical bond. In one or more embodiments, a non-conductive inner liner  620  may be formed in the annulus  352  of the outer sleeve  354  and adheres to the outer sleeve  354 . For example, non-conductive inner liner  620  forms a bond  610  with the outer sleeve  354 . The non-conductive inner liner  620  may comprise a composite material. In one or more embodiments, the non-conductive inner liner  620  comprises the composite material as the non-conductive insert  356 . The non-conductive inner liner  620  may be formed by any one or more processes including, but not limited to, molding, such as injection molding, subtracted machining, fusing, curing, bonding, masking, any other suitable process or procedure, or any combination thereof. The non-conductive inner liner  620  adheres, fuses, bonds or otherwise affixes to the outer sleeve  354  such that no or only substantially inconsequential air gaps exists between the non-conductive inner liner  620  and the outer sleeve  354 . In one or more embodiments, non-conductive inner liner  620  may be a sleeve that is circumferentially formed in the annulus  352 . In one or more embodiments, non-conductive inner liner  620  may be formed on one or more portions of or partially circumferentially formed on the outer sleeve  354  in the annulus  352 , for example, as illustrated in  FIG. 6 . For example, the non-conductive inner liner  610  is circumferentially disposed or positioned or otherwise formed in the annulus  352  to form a sleeve that adheres to the outer sleeve without any or with only inconsequential air gaps.  FIG. 7  illustrates a partial cross-sectional view of a sleeve assembly  350 , according to one or more aspects of the present disclosure. For example, a non-conductive inner liner  620  may form a button-shaped or flanged insert  710 . The non-conductive inner liner  620  provides additional structure to maintain the placement or bonding of the inner insert  356  in the slot  358 . 
       FIG. 10  is a flowchart of a logging operation, according to one or more aspects of the present disclosure. At step  1002 , a logging tool, such as logging tool  126  of  FIG. 1 , is disposed in a wellbore  104  of a formation  106 . The logging tool  126  may comprise a sleeve assembly  350 . An antenna of the sleeve assembly  350 , such as antenna assembly  302  of  FIG. 3 , may be aligned, at least partially, at step  1004  with a slot  358  disposed in or about an outer sleeve  354  of the sleeve assembly  350 . At step  1008 , the antenna communicates or transmits a signal through a non-conductive insert  356  disposed in the slot  358  to the formation  106 . At step  1012 , the logging tool  126  or an antenna of the logging tool  126  receives a return signal. The non-conductive insert  356  comprises a composite material that permits transmission of the signal and receipt of the return signal. At step  1016 , the return signal is logged, for example, by a logging facility  206 , a surface receiver, a telemetry module  128  or any other logging or memory device. In one or more embodiments, the logging tool utilizes mud telemetry to communicate the return signal to the logging facility  206 . In one or more embodiments, the transmitted signal and the return signal are communicated through a non-conductive inner liner comprised of a composite material. 
     Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces.