APPARATUS AND METHOD FOR CONSTRUCTING A MODULAR LOGGING-WHILE-DRILLING TOOL

Abstract

In one embodiment the application pertains to a logging-while-drilling tool comprising an inner bore with a distal end and a proximal end. The inner bore of the LWD tool comprises: at least one sensor to measure a property of the formation around a wellbore; a power unit; and a short-hop transmitter configured to communicate with a short-hop receiver of an MWD system. A processor in the inner bore is configured to acquire, process, and store formation data. The processor is operably connected to the short-hop transmitter such that at least a portion of the formation data can be communicated to the short-hop receiver of an MWD system.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application Ser. No. 63/744,525 filed Jan. 13, 2025 which application is incorporated herein by reference. The application is also related to the following of Applicant's patents and publications: U.S. Pat. Nos. US2015293254A1; U.S. Pat. No. 12,078,057B1; US2021079782A1; US2014368350A1; U.S. Pat. No. 12,228,027B2; US2015107900A1; US2023135986A1; US2014368200A1; U.S. Pat. Nos. 10,365,391B2; 10,591,635B2; 11,725,462B1; and US2016124107A1 all of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to an apparatus and method for constructing a modular logging-while-drilling tool.

BACKGROUND AND SUMMARY

Logging-while-drilling (LWD) tools are often essential parts of geosteering, well placement, and formation evaluation operations. For instance, a resistivity LWD tool is often used to detect lithology changes, identify the direction of an approaching bed boundary, and/or warn of an over-pressured zone ahead of the drill bit. A sonic LWD tool may be used to determine formation porosities and/or provide formation impedance information to facilitate seismic-well ties. A density LWD tool can be used to provide detailed formation layering information around a wellbore. Other LWD tools have also been in uses including neutron, nuclear magnetic resonance, resistivity imaging, and deep-reading resistivity LWD tools.

One drawback of the existing LWD tools is that they need wired connections to an MWD system for power and/or data communications. The data acquired by an LWD tool is usually fed to an MWD system for transmission to surface. An MWD system may also need to supply power through the wires to the LWD tool. Unfortunately, such connections often involve complex devices such as flow diverters and/or data links for collar-to-sonde or collar-to-collar transitions. The wired connections not only represent higher risks of operational failures but also put restrictions on where an LWD tool can be placed in a bottom-hole assembly (BHA).

It would desirable if LWD systems and methods could be developed that reduced and/or eliminated the need for wired connections. It would further be desirable if such systems and methods were modular to provide for flexibility of configurations and/or replacement of worn components. It would further be desirable if new systems and processes reduced the manufacturing costs, reduced the operational risks of running LWD tools, and/or improved the reliability downhole.

Advantageously, the systems and processes described herein meet one or more up to all of the aforementioned needs. In one embodiment the application pertains to a logging-while-drilling tool comprising an inner bore with a distal end and a proximal end. The inner bore of the LWD tool comprises: at least one sensor to measure a property of the formation around a wellbore; a power unit; and a short-hop transmitter configured to communicate with a short-hop receiver of an MWD system. A processor in the inner bore is configured to acquire, process, and store formation data. The processor is operably connected to the short-hop transmitter such that at least a portion of the formation data can be communicated to the short-hop receiver of an MWD system.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawing with a full description of each figure in the examples section below.

FIG. 1 shows an exemplary modular LWD tool as described herein.

FIG. 2 shows an exemplary modular resistivity LWD tool as described herein.

DETAILED DESCRIPTION

This application pertains to a modular LWD tool such as a modular resistivity LWD tool which advantageously may communicate with an MWD system in the absence of wired connections between the LWD tool and MWD system.

The tool consists of four distinct subsystems: (1) an LWD sensor subsystem comprising (2) a power subsystem, (3) a short-hop subsystem, and (4) an electronics subsystem that comprises one or more processors. In some embodiments all the subsystems are internally connected mechanically, electrically, or both. Advantageously, no wired connection to an MWD system is required on the bottom hole assembly (BHA).

All the subsystems on the LWD tool are preferably packaged in a single collar. Some of the subsystems, e.g., the power subsystem, may be optionally packaged in a sonde that is placed in the inner bore of the collar and wired connected to the other subsystems on the collar. Some of the subsystems, e.g., the short-hop subsystem, may be optionally packaged on a secondary collar that is wired connected to the first collar. An exemplary LWD is shown in FIG. 1.

The modular LWD tool is further exemplified with a resistivity LWD tool. Refer to FIG. 2. The sensor subsystem comprises at least one transmitting antenna and at least one receiving antenna. The antennas have magnetic moments either oriented in the direction of the longitudinal axis of the tool or at angles with the longitudinal axis of the tool. The electronics subsystem acquires and processes signals from the antennas to yield information about the formation resistivity and/or distance to and direction of an adjacent bed boundary. The power subsystem may contain lithium batteries or turbine generators or both. The short-hop subsystem will consist of a transmission antenna that can be an electrical gap, a coil antenna, an acoustic transducer, a mud pulser, or any other form or combination of mechanisms suitable for data transmission. The short-hop receiver connected to an MWD system receives and decodes the transmitted data from the modular LWD and feeds it to the MWD system for further transmission to surface.

An LWD tool constructed according to the invention may be placed anywhere in a BHA, provided that the short-hop receiver on the MWD end is within the range of the short-hop communications and proper mechanical connections are provided to connect the tool to the rest of the BHA.

In the preceding specification, various embodiments have been described with references to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded as an illustrative rather than restrictive sense.

Claims

1. A logging-while-drilling tool comprising:

an inner bore with a distal end and a proximal end wherein the inner bore comprises: at least one sensor to measure a property of the formation around a wellbore; a power unit; a short-hop transmitter configured to communicate with a short-hop receiver of an MWD system; and an electronics subsystem comprising a processor configured to acquire, process, and store formation data wherein the processor is operably connected to the short-hop transmitter such that at least a portion of the formation data can be communicated to the short-hop receiver of an MWD system.

2. The logging-while-drilling tool of claim 1 wherein the sensor comprises at least one receiving antenna and at least one receiving antenna.

3. The logging-while-drilling tool of claim 2 wherein the at least one transmitting antenna and the at least one receiving antenna each have a magnetic moment oriented in the direction of the longitudinal axis of the tool.

4. The logging-while-drilling tool of claim 2 wherein the at least one transmitting antenna and the at least one receiving antenna each have a magnetic moment oriented at an angle with respect to the longitudinal axis of the tool.

5. The logging-while-drilling tool of claim 2 wherein the electronics subsystem acquires and processes signals from the at least one receiving antenna and the at least one receiving antenna to yield information about the formation resistivity.

6. The logging-while-drilling tool of claim 2 wherein the electronics subsystem acquires and processes signals from the at least one receiving antenna and the at least one receiving antenna to yield information about the distance to an adjacent bed boundary.

7. The logging-while-drilling tool of claim 2 wherein the electronics subsystem acquires and processes signals from the at least one receiving antenna and the at least one receiving antenna to yield information about the direction of an adjacent bed boundary.

8. The logging-while-drilling tool of claim 1 wherein the power unit comprises lithium batteries.

9. The logging-while-drilling tool of claim 1 wherein the power unit comprises turbine generators.

10. The logging-while-drilling tool of claim 1 wherein the power unit comprises lithium batteries and turbine generators.

11. The logging-while-drilling tool of claim 2 wherein the transmission antenna comprises an electrical gap, a coil antenna, an acoustic transducer, or a mud pulser.

12. A system comprising:

a logging-while-drilling tool comprising: an inner bore with a distal end and a proximal end wherein the inner bore comprises: at least one sensor to measure a property of the formation around a wellbore wherein the sensor comprises at least one receiving antenna and at least one receiving antenna; a power unit; a short-hop transmitter configured to communicate with a short-hop receiver of an MWD system; and an electronics subsystem comprising a processor configured to acquire, process, and store formation data wherein the processor is operably connected to the short-hop transmitter such that at least a portion of the formation data can be communicated to the short-hop receiver of an MWD system; and an MWD system which is separate from and lacks a wired connection to the logging-while-drilling tool wherein the MWD system comprises a short hop receiver configured to wirelessly receive and decode transmitted data from the a short-hop transmitter of the logging-while-drilling tool.

13. The system of claim 12 wherein the MWD system is configured to transmit decoded data for transmission to a surface.

14. The system of claim 12 wherein the logging-while-drilling tool is a resistivity tool.