10121-4504-01-PR-Final_Intelligent_Casing-Intelligent_Formation_Telemetry_System-06-20-14

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Intelligent Casing-Intelligent Formation Telemetry (ICIFT) System10121-4504-01Dr. Harold StalfordUniversity of Oklahoma

RPSEA Ultra-Deepwater Drilling, Completions, and Interventions TAC MeetingJune 4, 2014Greater Fort Bend Economic Development Council Board Room, Sugar Land, TX

rpsea.org

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Acknowledgement

We would like to offer our sincere thanks to theDepartment of Energy, RPSEA, Drill Right Technology, and the Ultra-Deepwater committee members for providing the University of Oklahoma with this opportunity to develop the Intelligent Casing-Intelligent Formation Telemetry (ICIFT) System

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Project Participants

Principal Investigators:• Dr. Harold Stalford, Professor of AME, OU• Dr. Ramadan Ahmed, Assistant Professor of PE, OU

Industrial Professional:• Darrell Husted, CEO/President, Drill Right Technology, Inc., Oklahoma City, OK

Research Assistants:• Jason Edwards, AME, OU• Victor Hugo Soriano Arambulo, PE, OU• Mounraj Sharma, PE, OU• Jeremy Friesenhahn, EE & CE, OU• Ryan Bott, CS, OU• Michael Nash, AME, OU

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Overall Objective ICIFT System

Intelligent Casing/Intelligent Formation Telemetry

• Enhance downhole data gathering from points external to the casing

• Allow much more reservoir data to be transmitted

• Allow real-time data transmission during cementing of prod. casing

• Prevent loss of well control incident by early identification

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Main Objective: ICIFT System

RFID & Wireless Sensor Telemetry Technologies

Pressure, Temperature, Flow Sensor Data

Integration of Technologies in Prototype Development

Laboratory Testing & Evaluation of RF Signals Transmission

through Cement, Rock Formations, Fluids

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Outline

o Literature Survey & Background Studies

o Assess. of Borehole Telemetry System Comp.

o Design and Development of RFID Sensor & Transceiver Prototypes

o Laboratory Testing of Prototypes & Telemetry Network

o Communication of Sensor Data to Surface

o Conclusions & Technology Transfer

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Literature Survey and Background Studies

Concept/Principles of Intelligent System

Fiber Optic Sensing (Real-Time, Distributive)

Instrumented Casing (History and Technology)

Borehole Telemetry (Data Transmission: Capabilities and

Reliability)

Sensor technologies (Measurements: Wired and Wireless)

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Principles of Intelligent System

P1: Permanent Downhole Components (life of well)

P2: Wells Remotely Monitored & Controlled from Surface; Zonal

Isolation & Multi-Zone Deployments

P3: Provide Real-Time Data

P4: Optimize Production, Increase Ultimate Reservoir Recovery,

Reduce Overall Costs, Accelerate Cash Flow, Maximize Net Present

Value (NPV)

P5: Reduce Physical Interventions, Provide Well Integrity

Monitoring, Improve HSE Issues

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Telemetry Systems

Wired Telemetry Systems Wireline System

Wired Drill Pipe Telemetry System

Fiber Optic System

Non Wired Telemetry Mud Pulse Telemetry

Electromagnetic Telemetry

Acoustic Telemetry

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Monitoring Systems: Components & Failures(Permanent Downhole Sensors)

o Electronic gauges (20% failures)o Gauge mandrelso Connectors (50% failures)o Cables (25% without being splice free)o Acquisition systemo Interpretation softwareo Power supply

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Factors to Consider(Permanent Downhole Sensors)

o Minimize: downhole electronicso Minimize: number of partso Minimize: number of moving partso Use appropriate coatings, packaging technology, & housingo Consider non-electronic sensors (i.e., fiber optic)o Consider “right” mix (electronic, fiber optic, electrode array)o Consider materials for HT/HP UDW applications (e.g., quartz, fiber optic,

etc.)o Consider fiber optic sensor issues:- must be appropriately coated and protected (otherwise, ingression of

OH- molecules into fiber)- drifting (changes of zero offset)

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Fiber‐Optic Distributive Sensing

Distributive sensing, permanent well monitoring

High-bandwidth, Low-loss transmission medium

High information transmission rates (1x1012 b/s)

No downhole electronics, immune EM radiation

Installation any length

Flexible configurations, greater sensitivity

Very thin (e.g., human hair), Cheap (relatively)

Slide 12

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Fiber-Optic DTS Deployed Outside Casing

Over 70 wells with DTS permanent installations:- Successfully tested, proved and applied DTS technology for monitoring injection profile in major onshore waterfloodAll challenges met with 100% success:- Fiber deployed outside casing, cemented in place without creating a micro-annulus- Permitted perforations for completion without fiber damage- Control line and fiber pulled through wellhead mandrel- Fiber not damaged: rig move-out, well-head installation, etc.- Integrated into lean manufacturing style of drilling- Cheap enough for “low-cost” 20 BOPD environment

2013 SPE 163694 Rahman, et al., Aera Energy LLC

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Fiber-Optic Distributive Sensing

Distributive Sensing: DTS, DSS, DPS, DAS, DCSApplications: Monitoring & Profiling:Hydraulic fracture, well integrity, vertical seismic (VSP), gas-lift optimization, flow, sand

Coming Soon: Gas breakthrough, ESP, Micro-seismic, Multi-phase

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Wireless RFID Passive SAW Sensors

o Temperature, Pressure, etc. o Low Powero Ultra Small Size ( 1 mm diameters)o HT Rangeso Piezoelectric Material

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RFID SAW Sensors

Passive (no battery needed)

Operates in Liquid and Metal Environment

Wide Temperature Range (exceeds 300C)

Micro-second delays avoids clutter returns

Robustness to Gamma Ray exposure

Sensors include Temperature, Pressure, etc.

Surface Acoustic Wave (SAW)

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Literature Survey & Background Studies

Review: instrumented casing and borehole telemetry

Review: passive wireless SAW sensors that can measure pressure, temperature etc. lifetime of producing wells

Review: Instrumentation techniques that have potential to provide distributed real-time/continuous pressure, temperature and flow measurements

Integrated RFID sensor technology and application to borehole telemetry

Power supply options for RFID based ICIFT system

RF signal transmission in rock formation

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Assessment of Borehole Telemetry System Components

Wired Telemetry systemsWireline System (100-500 Kb/s)

Allow simultaneous measurements of formation propertiesDrilling assemblies must be pulled out of the borehole Measurement from different formations, but not in real drilling time

Wired Drill Pipe Telemetry System (50-500 Kb/s)A real time drill string telemetry network Allow a two-way data communication at 57000 bits/s Has reliability comparable with mud pulse system

Fiber Optic System (10-100 Mb/s)A distributive telemetry method using optical fibers The fiber serves as both sensor and telemetry channelIs comparable with electronic sensors in terms of performance, cost and simplicity of operation.

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Non Wired TelemetryMud Pulse Telemetry (1.5-40 b/s)

Most reliable and widely used telemetry method. Operates under harsh environments (20,000 psi and over 350°F).Data transfer rate is limited 12 bit/sWorks with incompressible fluids

Electromagnetic Telemetry (10-100 b/s)System uses the drill string as a dipole electrode.Higher data transfer rateApplicable in shallow wellsWorks with both compressible and incompressible

Acoustic Telemetry (10-30 b/s)Data is acoustically transmitted using the drill string System offers some degree of reliability for data transmissionHigh level of noise due to drilling operations must be overcomeMethods require the use of repeaters, depending on the well depth

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Telemetry System Components Sensors, Data processing Transmission systems Power supply

Relevant borehole conditions Depths, Temperatures, Pressures Borehole drilling and completion fluids Borehole formations

Performance Assessment Reliability, Power requirements, Data rates, Size requirements Costs

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Assessment of Borehole Telemetry System Components (cont.)

Evaluate different techniques Effectively place sensors at different depths of the well Reliably transfer real-time data to the surface Provide power to the system

Identify preferences (benefits & drawbacks) Deployment techniques Data transmission methods to surface Power transmission options Issues with wellbore and tree integrity

Preliminary well design Telemetry system components Sensor embedding procedures Reliable data transfer techniques Power supply systems

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Design/Development of RFID (Wireless) Sensor/Transceiver Prototypes

RFID Wireless Sensing Technology• RFID SAW Passive Sensors• Temperature & Pressure• RF telemetry through cement & formation media• RF telemetry through borehole fluids1

1RF through salt water (ocean): 5-10 MHz - 90 m - 500 Kbps

Design and develop RFID Sensor Telemetry prototypes

• Handle rock formations, and drilling and completion fluids

• Measure flow, pressure, and temperature sensors

• Permits high data rates at sufficient distances

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Rock FT-IR and Resistivity Analyseso FT-IR (Fourier Transform Infra-Red Spectroscopy) analysis

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22 Rock Samples

Claystone

Limestone

Sandstone

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Experimental Results

Wireless SAW SensorPassive (no battery)434 MHz

US Dime

Air 120Limestone >24Sandstone >24Claystone >24Concrete >24Water 16.5

Passive Wireless SAW Sensor (Pressure &Temperature)

R S

Reader (very low power)4mW

Media

Range (inches)Media

Measurements at 4mW Power Reader

Sensor: Temperature & Pressure

Range

Telemetry of Pressure & Temperature Data

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Design/Development of RFID (Wireless) Sensor/Transceiver Prototypes

Prototype designs based on state-of-the-art technology :• Sensors (RFID, SAW-based, Fiber optic-based)

Temperature &Pressure SAW sensors

• Power supply (low power considered) 4mW

• Rock formations & Fluids (drilling/completion) Cement, limestone, sandstone, water

• Wireless EM transmission frequencies 434MHz, 2.4 GHz

Experimental Results Good Match with Simulation Modeling

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Laboratory Testing of Prototypes and TelemetryNetwork

Laboratory Testing of Sensor and Transceiver Prototypes

Laboratory Testing of Telemetry Network• Test sequence of multiple prototypes

• Test rock formation/borehole fluids combo; test bidirectional

capability

• Evaluate overall performance of the telemetry network

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Laboratory Testing of Sensor/Transceiver Prototypes

Test and evaluate the performance of integrated components Passive wireless SAW sensors (T & P)

• Vary the type of obstruction (rock and formation fluids) Cement, limestone, sandstone, & water

• Attenuation of RF signal study Attenuation data good match with model


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Laboratory Testing of Telemetry Network

Lab test RF 2-way telemetry of prototype network RF 2-way wireless telemetry between 3 nodes of a preliminary

prototype network

• Rock formations Cement, sandstone, limestone

• Borehole fluids Water

Conducted preliminary tests in fiber optic based network system components


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Prototype ICIFT System (iBITS) (under development)

Two-way communicationbetween

surface command and UDW wellbore elements

(continuous, real-time, high data rate)

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ICIFT Systems Prototype Network

CentralData Center

Station 3

3000 ft. FO cable 3000 ft. FO cable

SAW RFID Sensors

Station 2Station 1

• Temperature• Pressure

Wireless Telemetry Wireless Telemetry Wireless Telemetry

SAW RFID Sensors SAW RFID Sensors



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Feedthroughs for Fiber-Optic Sensing?

On-Shore:Tubing Annulus: Feed-throughs are standardCasing Annulus: Feed-throughs are in use

Off-Shore:Tubing Annulus: Feed-throughs are in practiceCasing Annulus: Feed-throughs are in debate

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Feedthrough Issues Subsea Wellhead

Fiber-Optic Sensing: Off-Shore

Issues-Feedthrough in Casing Annulus:Sensors are needed in annulus to measure conditions (T, P, flow, etc.)What if significant temperature & pressure differences start to occurWhat if wellhead sensors in annulus stop working before lifetime of wellWhat if HP methane leak begins in feedthroughWhat if no one knows what is in annulus behind the feedthroughWhat if feedthrough in annulus creates well interventionWhat if a leak develops in a feedthroughWhat if…What if…

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Options: ICIFT SystemSensor (Discrete/Distributive)

Com

mun

icat

ion Wired/Wired

Wireless/Wireless

Wired/Wireless

Wireless/Wired

CopperFO

EMAcoustic

EM (RFID)Acoustic

PDGsFiber Optics (FO)

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Communication From Casing Annulus

A Starting Position

1. Use only Carbon Steel Casing (magnetic)

2. Do not cut a hole in the casing

At wellhead…downhole…in reservoir

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Communication Methods: No Holes& Through Steel Casing

1. Carbon Steel Casing (magnetic)o Ultrasonic-Based Wireless

2. Steel Casing (non-magnetic)o EM-Based Wireless

Sensor Data from Reservoir

Sensor Data to Annulus A

PT

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Slide 36

1Lawry et al. (2013). A High‐Performance Ultrasonic System for the Simultaneous Transmission of Data and Power Through Solid Metal Barriers, IEEE Trans. on Ultrasonics, Ferroelectrics, and Frequency Control, vol. 60, No. 1, January 2013.

Ultrasonic-Based Wireless Wellhead Concept

Ultrasonic Method: Communicate through carbon steel casing at wellhead

Transducers: PiezoelectricHigh-power: 50 Watts ac

High-Data Trans. Rate:Over 15 Mbps through 63.5 mm Steel barriers

Cross-section of the acoustic-electric channel (courtesy of Lawry et al., 20131)

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Slide 37

Non‐Mag‐Based Wireless Wellhead Concept

Provides telemetry from regions

outside production casing

ƚBenton Baugh (2013), “Method of non-intrusive Communication of Down Hole Annulus Information,” U.S. Patent Application. [Drawing: courtesy of Dr. Baugh]

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Communications at Wellhead

1. Carbon Steel Casing (magnetic)Ultrasonic-Based Wireless

2. Steel Casing (non-magnetic)EM-Based Wireless

3. Feed-ThroughsWired (e.g., Fiber optics)

4. Bypass WellheadEM-Based Wireless

PT


Sensor Data to SurfaceNo Hole

No Hole

Hole

No Hole

Byp

ass

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Slide 39

Feed-Throughs in Wellhead Concept

Casing Wellhead Feed-Throughs (mod in casing hangers)

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Intelligent Formation Concept(bypasses wellhead)

EM Wireless SystemOutside Casing/Formation-Based

• EM (e.g., 10 MHz)• Requires power

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Communications Reservoir Cross-over

EM-Based Wireless Link

Casing to Tubing Link

Special Casing Sub

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Sensor Data to Surface

PT

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Production Casing: EM-Based Wireless DesignSpecial Casing Sub (Concept)EM Wireless Communication

Requirements: Supersedes sub-sea standards of prod. casing

Annulus Clearance <2’’

EM Frequencies:10 MHz

External Data Transmitted:

Fiber-optic sensors,

RFID SAW, etc.

Production Casing Integrity not adversely affected

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ICIFT Systems

o Intelligent well technology outside casing/in cement/formation

o Wireless RFID SAW sensing

o Wired distributive sensing

o Configure best of wired and wireless combinations for UDW- in casing, on casing surface; in cement, in formation- wired sensors ; wireless sensors- passive sensors (no batteries); active sensors (batteries)- distributive sensors; discrete sensors

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ICIFT System (Cont.)Config. 1: Wellhead Feed-Throughs

o Wellhead feed-throughs allow for fiber-optic, power and communication cables

o Fiber-optics distributive sensors deployed outside casing (all FO electronics/processing done external to well)

o Wireless sensors (RFID passive) deployed outside casing in cement, in formation (downhole readers require power and electronics)

o Wired sensors (e.g., quartz) deployed along casing external surface require power and electronics

o Communications system- data telemetry to surface -required for downhole discrete sensors

o Wellhead feed-throughs must be secured against leaks

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ICIFT System (Cont.)Config. 2: Wellhead Acoustic-Based Passage

o Requires no holes in carbon steel casing at wellheado Ultrasonic piezoelectric-based systems provide high power

and high data rates through carbon steel casing wallso Downhole fiber-optics distributive sensors deployed outside

casing (requires downhole electronics/processing)o Wireless sensors (RFID passive) deployed outside casing in

cement, in formation (downhole readers require power and electronics)


o Communications system- data telemetry to surface -required for all downhole sensors

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ICIFT System (Cont.)Config. 3: Wellhead EM-Based Passage

o Requires non-magnetic casing at wellhead (but no holes)o EM-based systems provide high power and high data rates

through non-magnetic casing wallso Downhole fiber-optics distributive sensors deployed outside

casing (requires downhole electronics/processing)o Wireless sensors (RFID passive) deployed outside casing in

cement, in formation (downhole readers require power and electronics)


o Communications system- data telemetry to surface -required for all downhole sensors

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ICIFT System (Cont.)Config. 4: Reservoir-Based Passage

o Passage occurs below packer in reservoir near perforations region (holes in carbon steel casing are permitted there)

o Special casing sub with EM-based systems provides high power and high data rates

o Downhole fiber-optics distributive sensors deployed outside casing (requires downhole electronics/processing)



o Data telemetry to surface uses annulus between casing and production tubing

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ICIFT System (Cont.)Config. 5: Intelligent Formation EM-Based

o Wireless EM-based communications through formations to surface (bypasses wellhead)

o Requires sequence of wireless communication “towers” outside casing from downhole to surface

o Downhole fiber-optics distributive sensors deployed outside casing (requires downhole electronics/processing)



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Conclusions: ICIFT System

o Wireless/wired, discrete/distributive sensors outside casing

o Communication systems (telemetry to surface)- Fiber-optics feed-throughs in wellhead- Ultrasonic- passive sensors (no batteries); active sensors (batteries)- distributive sensors; discrete sensors

o Wired distributive sensing

o Configure best of wired and wireless combinations for UDW(configuration examples 1-5)

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Technology Transfer Activities

Reports:

Literature Survey & Background Studies


Design/Development: RFID Sensor & Transceiver Prototypes

Conference Presentations and Paper:

Intelligent Casing Design – ABC, Nov. 2013, Houston

Intelligent Casing-Intelligent Formation (ICIF) Design, OTC, May 2014

Intelligent Casing-Intelligent Formation (ICIF) Design, OTC25161-MS

Disclosure: The Intelligent Borehole Intranet Telemetry System (iBITS)

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THANK YOU

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Contacts

PI: Dr. Harold Stalford, ProfessorSchool of Aerospace and Mechanical EngineeringUniversity of [email protected](405) 325-1742

10121-4504-01-PR-Final_Intelligent_Casing-Intelligent_Formation_Telemetry_System-06-20-14

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