Patent ID: 12258852

DETAILED DESCRIPTION

Specific embodiments of the disclosure will now be described in detail with reference to the accompanying figures. In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well known features have not been described in detail to avoid unnecessarily complicating the description.

Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not intended to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.

In addition, throughout the application, the terms “upper” and “lower” may be used to describe the position of an element in a wellbore as described herein. In this respect, the term “upper” denotes an element disposed closer to the surface of the Earth than a corresponding “lower” element when the surveying system is in the wellbore, while the term “lower” conversely describes an element disposed further from the surface of the Earth than a corresponding “upper” element. Similarly, the term “downhole” may be used when referring to any position inside the wellbore beneath the surface. Likewise, the term “axial” refers to an orientation substantially parallel to an extension direction of a wellbore, while the term “radial” denotes a direction orthogonal to an axial direction. Similarly, the terms “vertical” and “vertically” refer to an axial direction (i.e., the primary extension direction of the wellbore) while the terms “lateral” and “laterally” refer to the radial direction orthogonal to a vertical direction.

In general, one or more embodiments of the present invention are directed towards a system for monitoring scaling and corrosion in a pipeline. The system includes a control system, a gauge cutter, a scale recorder, and a wireline. During the process of transporting oil or natural gas through a pipeline, particulates accumulate on the inner surface of the pipeline. The particulates may include, for example, calcium carbonate (limescale), iron sulfides, barium sulfate, strontium sulfate, or similar minerals. Due to being trapped below the surface of the Earth under high temperatures and pressures, the particulates are initially dissolved in the oil or other production fluids stored within the pipeline. As the oil is lifted through the pipeline, the temperature and pressure of the oil decreases, which causes the previously dissolved particulates to precipitate and accumulate on the sides of the pipeline. As the scaling accumulates, the pipeline may become closed off, preventing oil from being lifted through the pipeline. By surveying scaling in a pipeline in-situ, the proposed design advantageously detects scaling formation and other deposits in the pipeline at an early stage, preventing reduced production, decreased flow rate, or an increase in pressure drop.

FIG.1shows a schematic diagram illustrating an example of a well site11in accordance with one or more embodiments of the invention. In general, well sites11are configured in a myriad of ways. Therefore, the well site11is not intended to limit the particular configuration of the system for surveying internal pipeline scaling27. For example, the well site11is depicted as being on land, however the well site11can be offshore and monitoring the scaling27and corrosion in the pipeline19may be carried out with or without the use of a marine riser. Moreover, various components and details of the well site11that would be well known to a person of ordinary skill in the art have been omitted for the sake of brevity.

The process of monitoring the scaling27and corrosion in the pipeline19at the well site11is initiated by drilling a wellbore17into a subterranean formation25(“formation”). The formation25may include a porous or fractured rock formation that resides underground, beneath the Earth's surface15(“surface”). The surface15of the well site11is a reference position for where the wellbore17originates, and the wellbore17extends in an axial direction from the surface15. For the purpose of drilling the wellbore17into the formation25, equipment such as a crown block and derrick (not shown) suspends and rotates a drill string (not shown) to break the formation25and create the wellbore17. The pipeline19is installed in the wellbore17during drilling and transports oil or gas from a reservoir29in the wellbore17. The pipeline19may be formed of one or more varieties of steel (such as martensitic steel, duplex steel, or a steel alloy). As discussed above, as time passes, particulates accumulate on the interior wall of the pipeline19, and scaling27and corrosion can occur.

A wireline21is configured to lower tools into the pipeline19and comprises an electrical cable which can transmit data between a well control system13disposed on the surface15and the tools coupled to the wireline21. A plurality of tools may be coupled to the wireline21to gather downhole data. Specifically, in the current embodiment, a gauge cutter23is coupled to the wireline21and lowered into the pipeline19to dislodge and collect samples of scaling debris33which has accumulated in the pipeline19. In addition, a scale recorder (e.g.,FIG.2), connected to the gauge cutter23, is configured to generate scale recorder data, the scale recorder data comprising a location, a distribution, a texture, and a thickness of the scaling27in the pipeline19. The well control system13transmits instructions, via the wireline21, to the gauge cutter23and the scale recorder (e.g.,FIG.2) in real time to obtain scale recorder data, samples of scaling debris33, and an acoustic image of the scaling27in the pipeline19.

Turning toFIG.2,FIG.2depicts the gauge cutter23dislodging and collecting samples of scaling debris33from an inner wall of the pipeline19while the scale recorder49generates scale recorder49data and acoustic images of the scaling27in the pipeline19. The gauge cutter23further comprises a fluid permeable screen37and a cutting blade43. The fluid permeable screen37is configured to collect the scaling debris33dislodged by the cutting blade43through screen slots35, and the cutting blade43is a beveled edge at the lower most part of a conical section of the gauge cutter23configured to scrape debris from the pipeline19. Furthermore, the fluid permeable screen37is secured in place by an attachment tab41. The fluid permeable screen37is inserted beneath the attachment tab41which extends around the outer perimeter of the fluid permeable screen37.

The gauge cutter23further comprises an internal orifice39, a channel extending through the from the exterior housing47to the top of the fluid permeable screen37. The internal orifice39is configured to pass the scaling debris33taken in through the rectangular slots45of the exterior housing47into the gauge cutter23. An opening (not shown) at the top of the fluid permeable screen37allows the scaling debris33to enter the gauge cutter23. The screen slots35are configured to pass the scaling debris33taken in through the bottom slots (e.g.,FIG.3) into the gauge cutter23.

The scale recorder49is disposed in an exterior housing47, and the exterior housing47is connected to a lower most surface of the gauge cutter23. The exterior housing47comprises rectangular slots45to allow removed scaling debris33to enter the gauge cutter23while preventing the scaling debris33from impacting the scale recorder49. The scale recorder49is further disposed below the rectangular slots45of the exterior housing47. In addition, the scale recorder49is oriented coaxially with a vertical axis31that extends through the gauge cutter23, and the gauge cutter23comprises a first outer diameter in a direction orthogonal to the vertical axis31that is larger than a second outer diameter of the exterior housing47. For example, in the current embodiment, a plurality of scale recorders49are disposed in the exterior housing47and each scale recorder49is configured to receive a different reflected ultrasound wave after an incident ultrasound wave has been emitted from the plurality of scale recorders49and reflected on the scaling27on the pipeline19wall.

The scale recorders49emit ultrasound waves which are reflected on the scaling27on the pipeline19wall and received by the scale recorders49. The ultrasound waves are of a frequency between 2 Megahertz (MHz) to 18 MHz. The scale recorder49, discussed in more detail below, uses the ultrasound waves to determine properties of the scaling27on the pipeline19wall, as well as produce an acoustic image of the scaling27on the pipeline19wall. Acoustic imaging is a technique that uses sound waves to create visual representations of objects or environments. The technique comprises emitting sound waves which reflect off different surfaces and then measuring the reflected waves taking into account the amount of time taken for the wave to return, considering the medium through which the waves traveled through (e.g., air, water, oil, etc.), and the intensity of the waves. Processing these factors together generates detailed images or maps of the objects or environments being measured, and can provide spatial information a standard optical camera alone would be unable to provide.

Turning toFIG.3,FIG.3depicts a bottom view of the gauge cutter23and the exterior housing47comprising a plurality of scale recorders49. The cutting blade43extends from the gauge cutter23conically where the edge comprises a beveled edge to scrape and dislodge scaling debris33from the pipeline19wall. The first outer diameter of the cutting blade43(and thus the gauge cutter23) is larger than the second outer diameter of the exterior housing47, shown in the interior circle. Between the cutting blade43and the exterior housing47, the gauge cutter23comprises a plurality of bottom slots53configured for passing scaling debris33into the gauge cutter23. The current embodiment depicts the exterior housing47comprising six scale recorders49, however the exterior housing47may comprise one or more scale recorders49at the discretion of the operator.

Turning toFIG.4,FIG.4depicts a diagram of the scale recorder49. The scale recorder49comprises an ultrasound wave transmitter55, an ultrasound wave receiver57, a processor59, a memory61, and a communication interface63. The ultrasound wave transmitter55is configured to emit incident ultrasound waves with a frequency between 2 MHz to 18 MHz. The ultrasound wave receiver57is configured to detect reflected ultrasound waves received from the interior wall and scaling27of the pipeline19. Additionally, the ultrasound wave receiver57is further configured to generate scale recorder data based upon the reflected ultrasound waves, the scale recorder data comprising a location, a thickness, a distribution, and a texture of the scaling27disposed on the interior wall of the pipeline19. The processor59is configured to analyze the scale recorder data and produce an acoustic image of the pipeline19and scaling27on the interior wall of the pipeline19. The memory61, comprising a non-transient storage medium, is configured to store the acoustic image and the scale recorder data. Finally, the wireline21is coupled to the control system and the communication interface63, allowing the control system and scale recorder49to communicate in real time. The control system is configured to send instructions to the scale recorder49to obtain the scale recorder data and acoustic images, and the scale recorder49is further configured to transmit the scale recorder data and the acoustic image to the control system via the communication interface63.

The acoustic image utilizes ultrasound waves within a frequency of 2 MHz to 18 MHz because waves within this frequency range can pass through the accumulated scaling27and be reflected off of the pipeline19itself. The specific frequency implemented is decided at the discretion of the operator or manufacturer.

Further discussing the process of producing an acoustic image, an acoustic image can be defined as an image encompassing a level of scaling27at a corresponding depth of the pipeline19, such that the acoustic image depicts a part or all of the pipeline19, as well as a level of scaling27present in the depicted portion of the pipeline19. The acoustic image is produced when mechanical vibrations, arising from sound, are translated into a visual representation of the ultrasound waves.

The emitted ultrasound waves from the ultrasound wave transmitter55pass through a first medium (e.g., air or oil) at a known rate, and pass through a second medium (i.e., the scaling27) at a second known rate, and finally reflect off a boundary (i.e., the interior wall of the pipeline19), and return as reflected ultrasound waves to the ultrasound wave receiver57. The thickness of the scaling27is a relative measure of the difference of time for the waves to pass through the first and second mediums. Thus, an acoustic image is produced taking into account the Time of Flight (ToF) taken for the emitted ultrasound waves to return as reflected ultrasound waves.

The current embodiment of the scale recorder49comprises one ultrasound wave transmitter55and one ultrasound wave receiver57, however the scale recorder49may alternatively comprise one or more ultrasound wave transmitters55at the discretion of the operator. If the system for surveying the scaling27on the interior wall of the pipeline19comprises only one ultrasound wave transmitter55, the incident ultrasound waves would likely need to be emitted in a radial direction orthogonal to the vertical axis31in order for only one ultrasound wave transmitter55to produce a complete acoustic image. However, the system comprises more than one ultrasound wave transmitter55, the incident waves may be emitted from multiple sources allowing for a complete mapping of the pipeline19to produce a complete acoustic image.

For example, the current embodiment inFIG.3shows six scale recorders49, all of which are emitting incident ultrasound waves and receiving reflected ultrasound waves. However, the scale recorder49may be configured to comprise multiple ultrasound wave transmitters55such that only one scale recorder49is necessary to emit incident ultrasound waves to map the entire desired area of the pipeline19. In this example, only one ultrasound wave receiver57is necessary.

Turning toFIG.5,FIG.5depicts a method for surveying the scaling27on the interior wall of the pipeline19in accordance with one or more embodiments of the invention. While the various blocks inFIG.5are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in a different order, may be combined or omitted, and some or all of the blocks may be executed in parallel and/or iteratively. Furthermore, the blocks may be performed actively or passively.

Initially, in Step510, a gauge cutter23is lowered into a pipeline19. A wireline21is used for lowering the gauge cutter23from the surface15of the well site11. The well control system13determines the rate at which the wireline21is lowered.

During Step520, instructions are sent from a well control system13to a scale recorder49, via the wireline21, to obtain scale recorder data. The scale recorder data comprises a location, a distribution, a texture, and a thickness of the scaling27disposed on an interior wall of the pipeline19.

In Step530, the scale recorder49receives the instructions from the well control system13through a communication interface63. The wireline21is coupled to the control system and the communication interface63, where the wireline21comprises an electrical cable configured to transmit data.

In Step540, an ultrasound wave transmitter55emits incident ultrasound waves. The ultrasound wave transmitter55is a component comprised within the scale recorder49and emits ultrasound waves at a frequency between 2 MHz and 18 MHz.

In Step550, an ultrasound wave receiver57detects reflected ultrasound waves received from the interior wall of the pipeline19and scaling27of the pipeline19. The incident ultrasound waves which were emitted by the ultrasound wave transmitter55become reflected ultrasound waves after traveling through a medium in the pipeline19(e.g., oil, water, air) and reflecting off the scaling27and the pipeline19wall. The ultrasound wave receiver57is further configured to generate the scale recorder data from the detected reflected ultrasound waves.

In Step560, a processor59analyzes the detected reflected ultrasound waves and the scale recorder data to produce an acoustic image of the scaling27on the interior wall of the pipeline19.

In Step570, the acoustic image and the scale recorder data are stored on a memory61. The memory61comprises a non-transient storage medium. In the case that the connection between the scale recorder49and the well control system13becomes disconnected, the memory61acts as a data backup that can be accessed after the gauge cutter23has been raised to the surface15.

In Step580, the acoustic image and the scale recorder data are transmitted from the communication interface63to the control system via the wireline21.

In Step590, the gauge cutter23dislodges scaling debris33from the interior wall of the pipeline19. The gauge cutter23comprises a beveled edge configured to scrape the scaling debris33from the pipeline19.

Finally, in Step600, after dislodging scaling debris33from the interior wall of the pipeline19, the gauge cutter23collects the dislodged scaling debris33for sampling. The gauge cutter23further comprises a fluid permeable screen37which collects the dislodged scaling debris33. The fluid permeable screen37comprises slots to allow the dislodged scaling debris33to pass through and be collected in the gauge cutter23.

Accordingly, the aforementioned embodiments of the invention as disclosed relate to systems and methods useful in detecting scaling27formation and other deposits in a pipeline19at an early stage, preventing reduced production, decreased flow rate, or an increase in pressure drop.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that may modifications are possible in the example embodiments without materially departing from the invention, for example, either multiple scale recorders49or a single scale recorder49comprising multiple ultrasound wave transmitters55may be used for the system. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.