Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    None. 
       BACKGROUND 
       [0002]    1. Technical Field 
         [0003]    This invention relates, in general, to testing and evaluation of subterranean formation fluids and, in one embodiment to a single phase fluid sampling apparatus with embedded transducers to evaluate and measure various aspects of the sampling process and to measure various parameters of the samples. The invention also relates to sampling apparatus for use in severe subterranean conditions. 
         [0004]    2. Background Art 
         [0005]    It is well known in the subterranean well drilling and completion art to perform tests on formations intersected by a wellbore. Such tests are typically performed in order to determine geological or other physical properties of the formation and fluids contained therein. For example, parameters such as permeability, porosity, fluid resistivity, temperature, pressure and bubble point may be determined. These and other characteristics of the formation and fluid contained therein may be determined by performing tests on the formation before the well is completed. 
         [0006]    One type of testing procedure that is commonly performed is to obtain a fluid sample from the formation to, among other things, determine the composition of the formation fluids. In this procedure, it is important to obtain a sample of the formation fluid that is representative of the fluids as they exist in the formation. In a typical sampling procedure, a sample of the formation fluids may be obtained by lowering a sampling tool having a sampling chamber into the wellbore on a conveyance such as a wireline, slickline, coiled tubing, jointed tubing or the like. When the sampling tool reaches the desired depth, one or more ports are opened to allow collection of the formation fluids. The ports may be actuated in variety of ways such as by electrical, hydraulic or mechanical methods. Once the ports are opened, formation fluids travel through the ports and a sample of the formation fluids is collected within the sampling chamber of the sampling tool. After the sample has been collected, the sampling tool may be withdrawn from the wellbore so that the formation fluid sample may be analyzed. 
         [0007]    In many situations it has been found that multiple samples are needed in many situations. Also, it has been determined that as the fluid sample is retrieved to the surface, the temperature of the fluid sample decreases causing shrinkage of the fluid sample and a reduction in the pressure of the fluid sample. These changes can cause the fluid sample to approach or reach saturation pressure creating the possibility of asphaltene deposition and flashing of entrained gasses present in the fluid sample. Once such a process occurs, the resulting fluid sample is no longer representative of the fluid conditions present in the formation. 
         [0008]    Accordingly, fluid samplers have been developed with the capacity to obtain and store multiple samples and with the capacity to maintain the samples at wellbore pressure during withdrawal from the wellbore. For example, samplers marketed by Halliburton Energy Services, Inc. under the trademark Armada® and the samplers disclosed in the Halliburton Energy Services, Inc.&#39;s. U.S. Pat. Nos. 7,472,589; 7,596,995; 7,874,206 and 7,966,876 are capable of obtaining multiple samples and utilize high pressure inert gas nitrogen containers to maintain the samples as wellbore pressures during recovery to the wellhead. The above listed Halliburton patents are incorporated herein by reference for all purposes. 
         [0009]    While these prior art samplers provide excellent sampling there are situations where these samplers are used in highly pressure, high temperature and corrosive well environments. Accordingly, the sample containers and nitrogen bottles in samplers used in these environments comprising a variety of expensive and exotic materials selected not to react with or contaminate the samples. 
         [0010]    To fit in the wellbore and provide an adequate capacity of the samples and supply of pressurizing gas, these sample containers and nitrogen bottles are made in a long and thin shape. Some containers and bottles are as long as about 15 feet which requires undesirable welding of these exotic materials that comprise these portions of the sampler. 
         [0011]    The existing fluid samplers are passive, in that they do not have a capacity to communicate with the surface. There have been occasions when for whatever reason the sampler did not obtain a sufficient sample. Accordingly, there is a need for a smarter fluid sampler which can measure the sampling process and parameters of the resulting sample and communicate these measurements to a surface operator or an embedded processor to initiate additional processes to obtain a proper sample. 
       SUMMARY OF THE INVENTIONS 
       [0012]    The present invention disclosed herein provides an improved single phase fluid sampling apparatus and a method for obtaining a fluid sample from a subterranean formation without the occurrence of phase change degradation of the fluid sample during the collection of the fluid sample or retrieval of the sampling apparatus from the wellbore. The sampling apparatus is capable of being suspended in the well from coil tubing, jointed tubing, a wireline, a slick line or the like. 
         [0013]    In addition, the sampling apparatus and method of the present invention are capable of maintaining the integrity of the fluid sample during storage on the surface. 
         [0014]    In one aspect the present invention is directed to an improved apparatus for obtaining a plurality of fluid samples in a subterranean well that includes a carrier, a plurality of sampling chambers and an inert gas pressure source. 
         [0015]    In another aspect of the present inventions, the carrier has a plurality of chamber receiving slots with separate sampling chambers are disposed within the chamber receiving slots. In addition, a plurality of pressurized gas bottle receiving slots with separate pressurized gas bottles are disposed within bottle receiving slots. 
         [0016]    In a further aspect of the present inventions, the sampling chambers and gas bottles comprise light weight non-metallic materials such as fiber reinforced composite. These fiber reinforced composite chambers and bottles and their component parts can be molded or formed by winding on a rotating mandrel. Fiber reinforced composite does not require welding and is inert and will not react with the sample. 
         [0017]    In an even further aspect of the present inventions, one or more of the following conductors, transducers, power sources, communicators, data memory and processors can be included in the sampler assembly. 
         [0018]    In an additional aspect of the present invention, one or more of the following conductors, transducers, power sources, communicators, data memory and processors are embedded in the composite materials comprising the various components of sampler assembly. 
         [0019]    In a further aspect of the present inventions, the sampling assembly measures one or more of the temperature, pressure, volume, electrical conductivity, electrical resistance, radioactivity and composition of the sample contained in at least one of the plurality of sampling chambers. 
         [0020]    In an additional aspect of the present inventions, the sampling assembly measures one or more of the temperature and pressure of the wellbore fluids external to the sampling assembly. 
         [0021]    In an even further aspect of the present inventions, data relating to the sample and or well fluid is communicated from the sampling apparatus to the surface and or stored in the sampling assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The drawings are incorporated into and form a part of the specification to illustrate at least one embodiment and example of the present invention. Together with the written description, the drawings serve to explain the principles of the invention. The drawings are only for the purpose of illustrating at least one preferred example of at least one embodiment of the invention and are not to be construed as limiting the invention to only the illustrated and described example or examples. The various advantages and features of the various embodiments of the present invention will be apparent from a consideration of the drawings in which: 
           [0023]      FIG. 1  is a schematic illustration of an embodiment of the fluid sampler system embodying principles of the present invention; 
           [0024]      FIG. 2  is a perspective view of the sampler system embodying principles of the present invention; 
           [0025]      FIG. 3   a - f  are cross-sectional views of successive axial portions of a sampling section of a sampler system embodying principles of the present invention; 
           [0026]      FIG. 4  is a schematic of the components forming the sampling section; 
           [0027]      FIG. 5  is an enlarged cross-sectional view of a portion of the sampling section; and 
           [0028]      FIG. 6  is cross-sectional views of the inert gas bottle of the present invention of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    Referring initially to  FIG. 1 , therein is representatively illustrated a fluid sampler system  10  and associated methods which embody principles of the present invention. The embodiment illustrated in this figure is particularly adapted for connection to and suspension from a tubular member. A fluid sampler assembly  18  is connected in tubular string  12  by connection means, such as, threads at its upper end. In the embodiments (not illustrated) that are adapted to attached to wire or slick line equipment the attachment means comprises a coupling adapted to provide electrical connection to the wire or slick line. 
         [0030]    A tubular string  12 , such as a drill stem test string, is positioned in a wellbore  14 . An internal flow passage  16  extends longitudinally through tubular string  12 . Also, preferably included in tubular string  12  are a circulating valve  20 , a tester valve  22  and a choke  24 . Circulating valve  20 , tester valve  22  and choke  24  may be of conventional design. It should be noted, however, by those skilled in the art that it is not necessary for tubular string  12  to include the specific combination or arrangement of equipment described herein. It is also not necessary for sampler  18  to be included in the tubular string  12  since, for example, sampler  18  could instead be conveyed through flow passage  16  using a wireline, slickline, coiled tubing, downhole robot or the like. When using the wire and slick line equipment the sampler  18  can be connected to communicate to the well head through the wire and slick lines. Although wellbore  14  is depicted as being cased and cemented, it could alternatively be uncased or open hole. 
         [0031]    In a formation testing operation, tester valve  22  is used to selectively permit and prevent flow through passage  16 . Circulating valve  20  is used to selectively permit and prevent flow between passage  16  and an annulus  26  formed radially between tubular string  12  and wellbore  14 . Choke  24  is used to selectively restrict flow through tubular string  12 . Each of valves  20 ,  22  and choke  24  may be operated by manipulating pressure in annulus  26  from the surface, or any of them could be operated by other methods if desired. 
         [0032]    Choke  24  may be actuated to restrict flow through passage  16  to minimize wellbore storage effects due to the large volume in tubular string  12  above sampler  18 . When choke  24  restricts flow through passage  16 , a pressure differential is created in passage  16 , thereby maintaining pressure in passage  16  at sampler  18  and reducing the drawdown effect of opening tester valve  22 . In this manner, by restricting flow through choke  24  at the time a fluid sample is taken in sampler assembly  18 , the fluid sample may be prevented from going below its bubble point, i.e., the pressure below which a gas phase begins to form in a fluid phase. Circulating valve  20  permits hydrocarbons in tubular string  12  to be circulated out prior to retrieving tubular string  12 . 
         [0033]    Even though  FIG. 1  depicts a vertical well, it should be noted by one skilled in the art that the fluid sampler of the present invention is equally well-suited for use in deviated wells, inclined wells or horizontal wells. As such, the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. 
         [0034]    In  FIG. 2 , a sampler assembly  18  includes an upper connector  32  and lower connector  34  for coupling in a tubing string. An actuator section  36  is positioned below the upper connector and axially below the actuator section is a sample carrier section  38 . The sampler assembly includes a central passageway  40  which provides a smooth bore through fluid sampler. As illustrated a plurality of fluid sampling chambers  100  are mounted in slots in the carrier section  38 . 
         [0035]    The operation and detail structure of the actuator section  36  are described in U.S. Pat. No. 7,966,876, which is incorporated herein by reference for all purposes. In general terms the actuator sections contains a plurality of passageways and valves that in response to an external input (such as, electrical, electromagnetic signal or pressure change) will connect an inlet passageway in the upper end of one or more of the sampling chambers  100  to the fluid in the wellbore. After the well fluid has been collected in the chambers  100  the actuator will disconnect the chambers  100  from the wellbore trapping the sample in the chamber. 
         [0036]    In  FIGS. 3A-3F , a fluid sampling chamber that embodies principles of the present invention is representatively illustrated and generally designated by reference numeral  100 . The upper portion  102  of the sampling chamber  100  (See  FIG. 3A ) is provided with seals  104  on one end for mounting in the sample carrier section  38 . The other end of upper portion is threaded into a nipple  108 . The nipple  108  is connected to an elongated tubular section  109  by threads  111 . 
         [0037]    A passage  110  extends through the upper portion  102  and is mounted in the communication with an internal fluid passageway  112  in the nipple  108 . A normally closed sample collecting solenoid valve  116  is opened by a command signal conducted form the surface or an internal controller in the sampler assembly  18 . When the fluid sampling operation is initiated using actuator  36 , fluid enters passage  112  and passes into chamber  114  via valve  116 . Valve  116  permits fluid to flow from passages and  112   110  into sample chamber  114 , but prevents fluid from escaping from sample chamber  114 . 
         [0038]    Turning to  FIG. 3B , a debris trap piston  118  is mounted for reciprocal movement in tubular section  109  and separates sample chamber  114  from meter fluid chamber  120 . Debris trap piston  118  is illustrated having an internal debris chamber  126 . The seals in piston  118  isolate sample chamber  114  from a meter fluid chamber  120 . When a fluid sample is received in sample chamber  114 , piston  118  is displaced downwardly. The initially received fluid is typically laden with debris, or is a type of fluid (such as mud) which it is not desired to sample. Debris chamber  126  thus permits this initially received fluid to be isolated by a check valve (not illustrated) from the fluid that is later received in sample chamber  114 . The check valve can be a spring loaded plunger or flapper valve. 
         [0039]    As will be described herein in more detail, sensors and conductors are formed or mounted in or embedded in the wall of tubular section  109  to sense the position of the piston  118 . By sensing the position of the piston  118  the volume of the sample collected can be determined. In addition pressure and temperature transducers are mounted or embedded in the wall of tubular section  109  to provide readings of the pressure and temperature of the sample and of the wellbore fluids during and after sample collection. Alternatively, external transducers and data coupling  113  can be mounted on the exterior of tubular section  109 . The volume, pressure and temperature measurement data can be recorded and transmitted to the surface. In addition, other transducers for measuring other parameters, such as, electrical conductivity, electrical resistance, radioactivity and composition can be provided (mounted or formed) in the walls of the assembly  18 . 
         [0040]    In  FIGS. 3C  and D, the lower end of the tubular section  109  is illustrated threaded onto one end of a coupling  130 . A short tubular section  132  is threaded onto the other end of coupling  130  and an additional coupling  133  is threaded into the opposite end of tubular section  132 . The other end of coupling  133  is threaded into a tubular member  142  and a third coupling  144  is connected to the opposite end of tubular member  142 . 
         [0041]    As will be described, couplings  130  and  133  provide space for locating the electronics and processors associated with the pressure, temperature, volume, and other sample measuring transducers and sensors and for the data recording and transmission apparatus. An external power and data coupling  134  is provided for supplying power and control instructions to the fluid sampling chamber and for receiving data therefrom. In the wire line and slick line embodiments, connections to this surface can be made through coupling  134 . 
         [0042]    The meter fluid chamber  120  initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor  135  and a check valve  136  located in nipple  130  controls flow between chamber  120  and a meter fluid receiving chamber  138  formed in tubular member  142 . A piston assembly  140  reciprocates in tubular member  142  and separates chamber  138  from an atmospheric chamber  148 . Chamber  148  initially contains a gas at a relatively low pressure such as air at atmospheric pressure. By selecting a flow restrictor of appropriate size, the rate of collection of the sample can be controlled to insure sample quality. 
         [0043]      FIG. 3D  illustrates a piston assembly  140  mounted in chamber  138  to separate chamber  138  from atmospheric chamber  148 . Chamber  148  initially contains gases at a relatively low pressure, such as, air at atmospheric pressure. As metering fluid enters chamber  120 , piston  140  is forced to move downward away from the flow restrictor  134  and check valve  136 . As the piston assembly  140  moves down, the gases in chamber  148  are compressed. 
         [0044]    A rod  150  is carried by piston  140  and upon downward movement of the piston, the rod contacts a manifold  152  connected to coupling  144  to indicate that the sampling process is completed and to open gas supply valve  154 . (See  FIG. 3E .) A check valve  158  permits fluid flow from passage  156  into chamber  148 , but prevents fluid flow from chamber  148  to passage  156 . Lower section  160  has a threaded connector  162  with annular seals for connecting to the passageway  156  in nipple  144  and connecting passageway  146  in the sample carrier section  38  connected to a supply of pressurized gas. According to the present invention a pressure transducer is included in nipple  144  for measuring the pressure of the gas in the supply. 
         [0045]    By referring to  FIGS. 4 and 5 , the construction of the fluid sampling chamber  100  will be described. In general, the sampling chamber  100  comprises a plurality of tubular members connected together by unions. The entire sampling chamber  100  and its external component parts  102 ,  108 ,  109 ,  113 ,  130 ,  132 ,  133 ,  134 ,  142 ,  144 ,  152 , and  160  are molded, wrapped or otherwise formed substantially from materials that do not react with well fluids. In one embodiment the tubular sections could be substantially formed from materials comprising filament wound composite materials, wet wrapped composite materials, engineering grade plastics, including resins. In other embodiments, the materials complies molded resins with or without structural filaments added. It is known in the industry to use non-metallic plastic materials to form tubular sections of pipe, tubing and casing with internally threaded ends formed on these materials. 
         [0046]    The ends  102  and  160 , the nipples  108 ,  130 , 132 , and  144  and the mandrel  152  can be made from composite materials by molding or by filament winding with the external threads and other external and internal structures machined thereon. Likewise the internal pistons, valves and the like comprising the sampling chamber  100  could be formed by composite material by bonding or filament winding. Contamination of sample by corrosion will be eliminated with the use of non-metallic materials. 
         [0047]    According to other features of the present invention, transducers and conductors are embedded in the walls of the components of the sampling chamber  100 . In  FIG. 5  a cross section of the tubular section  109  formed from composite materials is illustrated. One or more conductors of  109   a  are embedded in the wall of tubular section  109 . The conductors can comprise metallic wire or carbon fibers in the form of a conductor (shown in  FIG. 5 ) or conductive layer (not shown) integrally formed during molding or winding. In one example embodiment, a metallic layer of mu-metal is embedded to provide magnetic shielding and form a conductive path. 
         [0048]    In addition transducers  109   b  can be molded into the wall of the sampling chamber components such as tubular section  109  as illustrated in  FIG. 5 . The conductor and transducer mounting concepts described and illustrated by example to section  109  would be utilized in the formation of the other components of the sampling chamber  100 . 
         [0049]    As mentioned above, one or more of the sampling chambers  100  (in this embodiment nine collection chambers  100  are present) are installed within exteriorly disposed chamber receiving slots of the carrier section  38 . An upper seal bore (not show) is provided in carrier  38  for receiving the upper portion of sampling chamber  102  and a lower seal bore (not shown) is provided for receiving the lower portion of sampling chamber  160 . 
         [0050]    In addition to the multiple sampling chambers  100  installed within carrier  38  an equal number of pressure sources  200  are present. Each of the passages  156  in lower sections  160  is in fluid communication with chambers  202  of pressure a sources  200  through passageways in carrier section  38  (not illustrated). An example of the pressure source  200  is illustrated in  FIG. 5 . The plurality of pressure sources  200  are mounted in a carrier similar to that illustrated in  FIG. 2 . In this manner a pressure source  200  is present to act against a piston  140  each sampling chamber  100 . The nitrogen piston  140  is used to maintain the samples at pressure during recovery. This pressure allows monophasic sampling and ensures that the fluid is an accurate representation of the well conditions. Preferably, compressed nitrogen at between about 7,000 psi and 12,000 psi is used to precharge chambers  202 , but other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired. 
         [0051]    The pressure source  200  embodiment illustrated in  FIG. 5  comprises upper  204  and lower  206  end caps and a central passageway  206 . Cylindrical sections  208  join the end caps to the central passageway to form chambers  202 . In another embodiment (not shown), the pressure source could be formed in a seamless manner, such as by molding or by filament winding. In this manner a unitary walled pressure source could be formed. 
         [0052]    According to a particular feature of the present invention the pressure source consists of materials that are nonmagnetic. According to a further embodiment the pressure source consists of non-metallic materials. In an additional embodiment, the pressure source substantially comprises engineering grade plastics. In another embodiment, the pressure source substantially comprises filament wound composite material. In a further embodiment, the pressure source substantially comprises wet wrapped composite material. 
         [0053]    While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods also can “consist essentially of” or “consist of” the various components and steps. As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. 
         [0054]    Therefore, the present inventions are well adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted, described, and is defined by reference to exemplary embodiments of the inventions, such a reference does not imply a limitation on the inventions, and no such limitation is to be inferred. The inventions are capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the inventions are exemplary only, and are not exhaustive of the scope of the inventions. Consequently, the inventions are intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects. 
         [0055]    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. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

Technology Category: 0