Abstract:
An apparatus for measuring a pipe within a well structure comprises a tubular body extending between first and second ends and having an inner surface defining a passage therethrough and an outer surface formed of a non-magnetic alloy metal. The apparatus further comprises a pair of flanges each connected to one of the first or second ends of the tubular body having a passage therethrough corresponding to the passage of the tubular body, each of the pair of flanges being connectable inline with the well structure. The apparatus further comprises at least one sensor stack being locatable around an outside of the tubular body comprising a sensor adapted to measure magnetic field strength and at least one magnetic stack being locatable around the outside of the tubular body comprising at least one magnet.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of Invention 
         [0002]    The present invention relates to well boring in general and in particular to a method and apparatus for measuring a pipe within a well structure. 
         [0003]    2. Description of Related Art 
         [0004]    In hydrocarbon production, a well may be formed by an outer casing located within a wellbore and may optionally be surrounded by cement. The well may then include a tool or production string therein for working or producing from the well. Due to the potentially high pressures within the well from hydrocarbons extracted from the hydrocarbon producing formation, numerous types of shut-off valves, spools and other fittings to isolate and control access to the well, such as, by way of non-limiting example a blow out preventer (BOP) stock, as it is commonly known or a snubbing unit. 
         [0005]    The well structure may include shut-off valves for closing off or otherwise completely or partially sealing the top of the well as desired by a user. In particular, one common design for such valves are pipe rams which utilize a pair of opposed rams which are movable along a plane perpendicular to the well bore. The rams may be moved along the plate by pistons or the like and are operable to be moved out of the central passage of the well or to be pressed together to seal the well. Rams may be of a blind or shear type to completely seal the well or of a pipe ram type in which the two rams each include a half-circle hole sized to pass a pipe therethrough when the two rams are pressed together. Such pipe rams are commonly utilized in snubbing units to seal around the drill or production string and isolate the well below the pipe ram from the environment while permitting the drill or production string to remain within the well or to be extracted or inserted into the well. 
         [0006]    One difficulty that exists with common hydrocarbon wells is the difficulty of determining the location of the connections on the tool or production string. Such strings are commonly formed of a plurality of endwise connected pipes which are connected to each other by threaded connectors. Conventionally such threaded connectors are located at each end and provide enlarged portions of the pipe which are strengthened so as to provide a larger stronger section of the pipe to be grasped by tools and the like. Such tool joints present a larger cross-section than the remainder of the pipe. Disadvantageously, such enlarged diameters of tool joints may interfere with the proper operation of pipe rams should the pipe ram be attempted to be closed at the location of such a tool joint or when extracting or inserting the pipe when at least one of the rams is set to hold back the pressure. Such an event is commonly referred to as stripping which may create a risk of the tool joint being pulled or pushed into the closed pipe ram thereby damaging the pipe and/or pipe ram. 
       SUMMARY OF THE INVENTION 
       [0007]    According to a first embodiment of the present invention there is disclosed an apparatus for measuring a pipe within a well structure. The apparatus comprises a tubular body extending between first and second ends and having an inner surface defining a passage therethrough and an outer surface formed of a non-magnetic alloy metal. The apparatus further comprises a pair of flanges each connected to one of the first or second ends of the tubular body having a passage therethrough corresponding to the passage of the tubular body, each of the pair of flanges being connectable inline with the well structure. The apparatus further comprises at least one sensor stack being locatable around an outside of the tubular body comprising a sensor adapted to measure magnetic field strength and at least one magnetic stack being locatable around the outside of the tubular body comprising at least one magnet. 
         [0008]    The tubular body may include at least one housing each extending around one of the at least one sensor stack or one of the at least one magnetic stack. Each housing may comprise a sleeve. The sleeves may be formed of a ferrous metal alloy. Each of said at least one sensor stack and said at least one magnetic stacks may extend radially from said tubular body. 
         [0009]    The sensor stack may comprise a sensor output a signal representing the diameter of the metallic object located within the central bore. The sensor may comprise a hall effects sensor. The sensor may be located at proximate to an outer surface of the tubular body. The sensor stack may include a magnet located at an end of the blind bore opposite to the sensor. 
         [0010]    The magnet stack may comprise at least one magnet. The magnet may comprise a plurality of magnets. The magnet may comprises rare earth magnets. The magnet may comprises electromagnets. 
         [0011]    The sensor stack and magnetic stack may be are arranged around the tubular body. The sensor stack and magnetic stack may be arranged at regular intervals around the tubular body. The sensor stack and magnetic stack may be arranged along a common plane perpendicular to an axis of the tubular body. The sensor stack and magnetic stack may be arranged along a plurality of planes. 
         [0012]    According to a further embodiment of the present invention there is disclosed a system for measuring a pipe within a well structure comprising a tubular body extending between first and second ends and having an inner surface defining a passage therethrough and an outer surface, the body being formed of a non-magnetic alloy metal. The system further comprise a pair of flanges each connected to one of the first or second ends of the tubular body having a passage therethrough corresponding to the passage of the tubular body, each of the pair of flanges being connectable inline with the well structure. The system further comprise at least one sensor stack being locatable around an outside of the tubular body comprising a sensor adapted to measure magnetic field strength, at least one magnetic stack being locatable around the outside of the tubular body comprising at least one magnet and a display adapted to receive an output from the at least one sensor stack and provide a display to a user indicating the diameter of an object within the tubular body. 
         [0013]    Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view, 
           [0015]      FIG. 1  is a cross-sectional view of the top end of a wellbore having an outer casing and a production string located therein with an apparatus for sensing the location of a pipe joint. 
           [0016]      FIG. 2  is a perspective view of the apparatus for sensing the location of a pipe joint according to a first embodiment of the present invention. 
           [0017]      FIG. 3  is a cross-sectional view of the apparatus of  FIG. 3  as taken along the line  3 - 3 . 
           [0018]      FIG. 4  is a cross-sectional view of the apparatus of  FIG. 3  as taken along the line  4 - 4 . 
           [0019]      FIG. 5  is an illustration of a display output showing voltage produced by a sensor of the apparatus of  FIG. 3  as a tool joint is passed therethrough. 
           [0020]      FIG. 6  is perspective view of an apparatus for sensing the location of a pipe joint according to a further embodiment of the present invention. 
           [0021]      FIG. 7  is a side view an apparatus for sensing the location of a pipe joint according to a further embodiment of the present invention. 
           [0022]      FIG. 8  is a cross-sectional view of the apparatus of  FIG. 1  with a pipe therein. 
           [0023]      FIG. 9  is a detailed cross sectional view of one of the magnetic stacks of the apparatus of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Referring to  FIG. 1 , a well assembly located within a well bore  8  of a soil formation  6  is illustrated generally at  10 . The well assembly includes a well casing  12  having top flange  14  which is securable to a pipe ram  16  or any other desired well head device. It will be appreciated that the present apparatus may be located at any location within the well, such as, by way of non-limiting example, the riser, snubbing stack, blow out preventer or any other well apparatus. It will also be appreciated that although only a single pipe ram is illustrated in  FIG. 1  for the sake of clarity, it will be appreciated that many installations will include more than one well head component. As illustrated in  FIG. 1 , the well assembly includes an apparatus for sensing a pipe joint according to a first embodiment of the invention, shown generally at  20  and one or more top pipe, well component or other equipment  18  located thereabove. A production or tool string  15  is located within the casing and includes a plurality of tool joints  17  therealong. 
         [0025]    The apparatus  20  senses the presence of the tool joint  17  and outputs a signal to a computer  88  and/or display  89  so as to indicate to a user that the tool joint  17  located within apparatus  20  so as to permit the user to advance the production or tool string  15  within the casing  12  by a predetermined distance so as to avoid having one of the pipe rams  16  or other well head devices engage upon the tool joint. 
         [0026]    With reference to  FIG. 2 , the apparatus  20  comprises a tubular member or body  22  extending between top and bottom ends,  24  and  26 , respectively and extending between inner and outer surfaces,  25  and  27 , respectively. The tubular member  22  includes a plurality of magnetic and sensor stacks,  70  and  80  extending therefrom as will be more fully described below. Optionally each of the sensor and magnetic stacks  70  and  80  may be contained within a housing, such as, by way of non-limiting example, a sleeve  40  extending from the outer surface of the tubular member  22 . As illustrated, the inner and outer surfaces  25  and  27  of the tubular member  22  are substantially cylindrical about a central axis  29  and the inner surface  25  defines a central passage  28  extending therethrough which may be sized and shaped to correspond to the interior of the casing  12 . As illustrated in  FIGS. 2 and 4 , the top and bottom surfaces of the top and bottom flanges  30  and  32  are substantially planar along a plane normal to the axis  29  and may optionally include a seal groove  36  extending annularly therearound for receiving a seal as are commonly known in the art. 
         [0027]    The apparatus  20  includes top and bottom flanges,  30  and  32 , respectively, adjacent to and connected to each of the top and bottom ends  24  and  26  of the tubular member so as to form a continuous body therewith. As illustrated, each of the top and bottom flanges  30  and  32  and the tubular member  22  includes the central passage  28  extending therethrough along a common central axis  29 . The top and bottom flanges  30  and  32  are sized to have a larger outer diameter than the tubular member  22  so as to overhang the tubular member and include a plurality of bores  34  therethrough for securing to adjacent structures within the well head, such as, by way of non-limiting example, pipe rams, or the like. Optionally, the apparatus may be formed as a hub clamp wherein the top and bottom flanges  30  and  32  may comprise clamping bodies adapted to clamp adjacent pipes as illustrated in  FIG. 6  as are commonly known. In operation, the top and bottom flanges  30  and  32  may be secured to such additional structures through the use of bolts or the like as is commonly known. Optionally, the apparatus may be formed as a hub clamp wherein the top and bottom flanges  30  and  32  may comprise clamping bodies adapted to clamp adjacent pipes as illustrated in  FIG. 6  as are commonly known. 
         [0028]    As set out above the tubular body  22  may optionally include a plurality of housings adapted to contain and protect the sensor and magnetic stacks  70  and  80  extending radially from the outer surface  27  of the tubular body. As illustrated in  FIGS. 2-4 , the housings may comprise sleeves extending radially from the tubular body  22 . It will be appreciated that the magnetic and sensor stacks  70  and  80  may also extend from the outside surface  27  of the tubular body  22  without such housing or sleeve therearound. As illustrated in  FIG. 3 , each of the sleeves  40  may be located at a position along the tubular body  22  so as to form a common plane  42  perpendicular to the central axis  29  of the apparatus. As illustrated in  FIG. 7 , the magnetic and sensor stacks  70  and  80  may also be arranged along more than one plane  42   a ,  42   b  and  42   c  so as to form sensor locations enabling a user to track the progress of a pipe through the apparatus  20 . 
         [0029]    The sleeves  40  comprise tubular members extending between first and second ends,  46  and  48 , respectively, and having inner and outer surfaces,  50  and  52 , respectively. The sleeves  40  may be formed of a substantially ferromagnetic material, such as steel so as to conduct magnetic flux as will be more fully described below. The sleeves  40  are selected to have a sufficient inner surface diameter sufficient to accommodate a magnetic stack  70  or a sensor stack  80  therein as more fully described below. By way of non-limiting example it has been found that a diameter of the inner surface of between 0.5 and 6 inches (13 and 152 mm) has been useful. The sleeve  40  may also have a length sufficient to receive the sensor and magnet stacks therein, such as by way of non-limiting example, between 0.5 and 6 inches (13 and 152 mm). Additionally, it will be appreciated that where other housing types are utilized, such housings may be formed of any suitable size to contain and protect the magnetic and sensor stacks from impacts or the like. 
         [0030]    Turning now to  FIGS. 3 and 4 , the sleeves  40  are arranged around the tubular body  22  along a common plane  42 . The common plane  42  is perpendicular to the central axis  29  and may be located at any height along the tubular body such as by way of non-limiting example, midpoint therealong as illustrated in  FIG. 3 . As illustrated in  FIG. 4 , the sleeves  40  may be arranged around the tubular body  22  at regular intervals. As illustrated herein, sleeves  40  are secured to the outer surface  27  of the tubular body  22  so as to form a blind bore  44  therewith. The sleeves  40  contain therein at least one magnetic stack  70  and at least one sensor stack  80  wherein the magnetic stack  70  forms a magnetic field within the interior of the central passage  28  and the sensor stack  80  measures changes in this magnetic field in response to an object passing therethrough. In particular, the magnetic stacks  70  and sensor stacks  80  may be alternated around the tubular body  22  and it will therefore be appreciated that an even number of sleeves will be required. It will also be appreciated that other arrangements of magnetic and sensor stacks may be useful as well. 
         [0031]    The magnetic stack  70  comprises a plurality of magnets sized to be located within the sleeve  40 . The magnets  60  are selected to have strong magnetic fields. In particular, it has been found that rare earth magnets, such as, by way of non-limiting example, neodymium, samarium-cobalt or electromagnets. Optionally, the magnets  60  may also be nickel plated or otherwise coated for corrosion resistance. 
         [0032]    The sensor stack  80  comprises a sensor  82  adapted to provide an output signal in response to the magnetic field in their proximity. By way of non-limiting example, the sensors  82  may comprise magnetic sensors, such as hall effect sensors although it will be appreciated that other sensor types may be utilized as. In particular it has been found that a hall effects sensor, such as a model SS496A1 sensor manufactured by Honeywell® has been particularly useful although it will be appreciated that other sensors will also be suitable. The sensors  82  are inserted into the sleeves  40  to be proximate to the first end  46  thereof and are retained within the sleeves by any suitable means, such as, by way of non-limiting example, adhesives, threading, fasteners or the like. The sensor  82  includes an output wires  86  extending therefrom as illustrated in  FIG. 1 . The output wire  86  is wired or otherwise connected to a computer  88  which optionally outputs to a display  89  and is therefore operable to provide an output signal representing the width of a metallic object located within the central passage  28  such as the drill string. 
         [0033]    The sensor stack  80  may also optionally include a magnet  84  located at the second end  48  of the sleeve  40 . The magnets  84  are selected to have strong magnetic fields. In particular, it has been found that rare earth magnets, such as, by way of non-limiting example, neodymium, samarium-cobalt or electromagnets. Optionally, the magnets  60  may also be nickel plated or otherwise coated for corrosion resistance. The magnets  84  are located at the second ends  48  of the sleeves  40  and retained in place by any suitable means, such as, by way of non-limiting example, adhesives, threading, fasteners or the like. 
         [0034]    The apparatus  20  may have any depth between the top and bottom surfaces as is desired by a user. Similarly, the top and bottom flanges  30  and  32  may have a thickness selected to provide sufficient strength to the apparatus so as to maintain the structural integrity of the well. Additionally, the apparatus will be selected to have an inner diameter of the inner surface  25  to correspond to the inner passage of the casing  12  for which it is to be used and an outer surface  27  diameter so as to provide a sufficient strength to maintain the anticipated pressure within the well according to well known means for the pressures and temperatures expected within the well bore. The tubular body  22  may be formed of a non-magnetic material, such as, by way of non-limiting example a nickel-chromium based alloy, such as Inconel® manufactured by Special Metals Corporation. It will also be appreciated that other materials may be useful as well, such as, by way of non-limiting example duplex and super duplex stainless steels provided they do not interfere with the sensor operation as described below. The top and bottom flanges  30  and  32  are formed of a ferrous alloy such as, by way of non-limiting example, 4130 and 4140 steel although other metals such as, by way of non-limiting example, super duplex and stainless steel, may be useful here as well. Optionally, the top and bottom flanges may also be formed of a similar non-magnetic material as the tubular body  22 . The flanges  30  and  32  and the tubular body  22  may be connected to each other through any known method such as, by way of non-limiting example, welding or the like so as to form a unitary body. 
         [0035]    With reference to  FIG. 5 , the output  100  may display the voltage signal outputted by the one or more sensors against time. During a first time period, the voltage signal will be at a first level, generally indicated at  102 , while a main portion of the pipe is drawn through the apparatus  20 . As the tool joint  17  is drawn through the apparatus  20 , the voltage output of the sensors  82  will be increased, generally indicated at  104 , due to the increased diameter of the metallic object within the central passage  28 . After the tool joint  17  passes the apparatus, the voltage will return to a lower level  106 . In such a manner, the display  100  will indicate to an operator when the tool joint  17  is located within the sleeve. Thereafter, the operator will be able to advance the production or tool string  15  by a known distance so as to ensure that the pipe rams  16  or other equipment avoids the tool joint  17 . The system may also optionally display a zero pipe condition generally illustrated at  108  in which the pipe is removed from the well bore. 
         [0036]    The sensors  82  may be calibrated prior to operation by locating a magnetic body of known size and position within the central passage  28  and adjusting the readout for each sensor  82   a ,  82   b  and  8   c  according to known methods. Thereafter, in operation, each of the sensors  82  measures a distance to the pipe as illustrated generally at  83   a ,  83   b  and  83   c  in  FIG. 8  wherein the measured distance from each of the sensors is then compared to each other to estimate the size and position of the tool string  15  or pipe utilizing triangulation according to known methods. As illustrated in  FIG. 8 , a single set of 3 sensors may be utilized to provide such location. It will be appreciated, that additional sets of 3 or more sensors may also be provided to provide an additional measure of the position of the pipe. Such multiple positions and size of the pipe may then be compared to and averaged with each other to improve accuracy of the system. 
         [0037]    Turning now to  FIG. 9 , a detailed cross sectional view of one of the magnetic stacks  70  is illustrated. As illustrated in  FIG. 9 , the magnetic stack  70  may be located within a sleeve  40  which also includes an actuator  120  and an actuator shaft  122  extending from the actuator  120  to the magnetic stack  70 . In operation, the actuator  120  may extend or retract the magnetic stack  70  into and out of engagement with the outer surface  27  of the tubular body  22 . In the retracted position, the magnetic field produced by the magnetic stack  70  will be reduced thereby permitting any ferromagnetic particles attracted thereto to be released from the interior of the central passage. 
         [0038]    While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.