DEVICES, SYSTEMS, AND METHODS FOR WELLBORE OPERATIONS
A system for performing logging operations within a horizontal section of a wellbore includes an anchor assembly securely positioned at or near the bottom of the well section and comprising a pulley collar. A looped cable line is connected to and operatively engages the pulley collar and extends to the surface, forming at least two accessible cable ends. A logging tool is selectively attachable to at least one cable end. The looped cable line and pulley collar cooperate to convey the logging tool from the surface into the horizontal wellbore section to perform logging operations and to subsequently retrieve the logging tool to the surface.
This application is a continuation-in-part application of, and under 35 U.S.C § 120 claims the benefit of, U.S. Patent Application Serial No.: 19/053,462, filed February 14, 2025, the entire contents of which is herein incorporated by reference.
TECHNICAL FIELDThe present disclosure relates generally to geothermal well tractors and wellbore conveyance systems.
BACKGROUNDIn recent years, exploration and development of geothermal energy resources have gained significant momentum, driven by the global demand for sustainable and renewable energy sources. Geothermal wells are often characterized by extreme temperatures and challenging subsurface conditions. Tractors are often required to convey tools and tool strings to designated locations within the geothermal well for specific operations. Due to the extreme temperatures and challenging subsurface conditions, tractor placement and movement presents unique operational challenges.
Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein:
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the principles disclosed herein. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein.
It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures, and components have not been described in detail so as not to obscure the related relevant feature being described. The drawings are not necessarily to scale and the proportions of certain parts may be exaggerated to better illustrate details and features. The description is not to be considered as limiting the scope of the embodiments described herein.
Disclosed herein is a geothermal wellbore tractor for conveying tools and tool strings within a geothermal wellbore. Typically, tractors, tools, and tool strings can be conveyed in geothermal wellbores via gravitational forces. However, traditional methods of deploying wireline tools, such as gravity-assisted conveyance, are ineffective in horizontal, slanted, and other non-vertical wells. In the case of geothermal wells, extreme temperatures and challenging subsurface conditions present unique operational challenges. Additionally, pumping methods, while useful in certain scenarios, are limited by the need for existing perforations or specific well constructions with annular spaces for fluid return.
Accurate subsurface evaluation in horizontal wellbores is critical for optimizing hydrocarbon recovery, reservoir evaluation and characterization, and ensuring efficient completion operations of wellbores. However, prior logging technologies and techniques for horizontal open-hole wellbores each come with significant trade-offs that limit their practicality, reliability, and efficiency, particularly under demanding conditions such as extended horizontal lengths, high temperatures, and complex operational scenarios.
Effective logging of well integrity, including casing inspection and cement bond inspection, is crucial for ensuring the safety, efficiency, and longevity of geothermal, hydrocarbon, and horizontal wellbores. Further, it may be necessary to take remedial action or maintenance to such wells for which tractor operations are also often necessary. In horizontal wells, placing wireline tools accurately and reliably in the desired sections for logging is a fundamental challenge. Addressing the need for precise and reliable placement of wireline tools in horizontal sections is essential for comprehensive well integrity logging. Casing inspection and cement bond inspection are critical tasks that ensure the structural integrity of the wellbore, detect potential issues early, and facilitate timely interventions. However, many of these tools, and the tractors that convey them, require electronic components that quickly degrade in high temperature environments, such as geothermal wellbores. The development of high-temperature tractors is imperative to overcome the limitations of current methods and enhance efficiency and accuracy of geothermal well logging operations.
Logging-while-drilling (LWD) systems provide real time formation of a wellbore evaluation. However, LWD systems are challenged by the need for specialized collars and durability requirements, leading to high costs. LWD systems are further challenged by telemetry constraints limiting real time transmission of data, which may be exacerbated in acoustic LWD systems. Power derived from downhole turbines for powering LWD systems may be unreliable or electrically noisy, influencing performance and data acquisition of an LWD system, including electromagnetic and magnetic resonance imaging logging tools. Prolonged exposure to harsh conditions, such as those in geothermal wellbores pose reliability concerns for LWD systems.
Pipe-conveyed wireline logging (PCWL) systems involve pushing a wireline logging tool to the target zone using drill pipe, followed by a wireline deployment for logging. PCWL systems provide high-quality data and robust power and telemetry systems but are challenged by slow deployment speeds, thereby increasing costs, and thermal exposure that degrades electronics compromising tool reliability. Ultra-slim through-bit logging systems offer faster deployment than PCWL systems, but are limited in logging capability and may produce the least quality data compared to PCWL or LWD systems. Ultra-slim through-bit logging systems often require specialized bits that may compromise optimal drilling performance and are incompatible with certain slim-hole drilling designs, restricting broad applications.
A tractor conveyed logging system of this disclosure presents efficient deployment speeds and flexible positioning. Moreover, the tractor conveyed logging systems of this disclosure overcome traction and friction challenges that previously impeded deployment and maneuverability of a tractor conveyed system. The tractor conveyed logging systems of this disclosure are more durable and mechanically resilient to extreme thermal and pressure environments in deep wellbores.
This disclosure also provides a modular tractor and logging (MTL) system with independent modules selectively deployable from within a wellbore. The MTL system incorporates a suite of downhole tool compartments or modules constructed as discrete, pressure-sealed modules that may be detached, exchanged, or upgraded in situ without requiring removal of the entire bottom hole assembly or MTL system. The MTL system may utilize automated, or artificial intelligence-based, diagnostic and optimization workflows that continuously assess tool health, sensor performance, and operational conditions, triggering selective module replacement upon identification of degradation, failure, or the availability of an improved module.
A retrieval and deployment mechanism enables transport of the modules in high-deviation or extended-reach wells, allowing the tractor to shuttle components directly to the surface or interface with wireline or slickline conveyances, e.g., using the pulley-based deployment systems described herein, including operation from intermediate positions to handle bi-directional movement of modules.
In addition, this disclosure provides a multi-segmented pipeline pig for inspection operations, wherein flexible, tether-connected pig segments traverse tight pipeline bends independently while carrying distributed sensors that dynamically adjust operational parameters in response to real-time measurements. Additionally, due to concerns over obstructing production flow, prior single pigs are infrequently deployed, limiting data collection frequency and leading to lower-resolution sensing. Previously, only a single pig is deployed at a time, further constraining the data-gathering capabilities. The multi-segmented pipeline pig of this disclosure is configured to mitigate obstruction of production flow and enable increased data gathering capabilities.
The multi-segmented pipeline pig may be used in conjunction with an MTL system described herein. The pig segments communicate wirelessly with fixed receivers along the pipeline, thereby enabling uninterrupted, continuous data acquisition without halting product flow. The system also deploys advanced fluid-analysis sensor modules above and below an Electric Submersible Pump (ESP), providing real-time detection of gas slugs or compositional changes and enabling automated pump-response adjustments and surface-level fluid routing. The MTL system may include modular ESPs configured as modular, compartmentalized assemblies whose individual pump sections are independently retrievable and/or replaceable. Using the tractor conveyance, a malfunctioning ESP module may be removed and replaced downhole without extracting the full pumping system.
Certain aspects provide significant operational benefits. Auto-alignment and wet-mate reconnection features allow replacement modules to lock in securely and restore power and data links instantly, minimizing downtime and eliminating the need for manual calibration. The tractor’s pass-through or bypass channel enables modules to move through the tractor without obstructing fluid flow, supporting continuous operation and allowing pressure-contained transfers. Additionally, fluid-monitoring modules equipped with active mixing elements produce more uniform samples, resulting in higher-accuracy measurements in multiphase or rapidly changing flow conditions.
A tractor 30 can be employed in an exemplary wellbore system 10 shown, for example, in
As illustrated, for example, in
The conduit 18 can be, for example, wireline, slickline, work string, coiled tubing, and/or any other suitable means for conveying downhole tools using a tractor 30 into a wellbore 14. The conduit 18 can be sufficiently strong and flexible to tether to the tractor 30 through the wellbore 14, while also permitting communication through the conduit 18 to one or more of the processors which can include local and/or remote processors.
It should be noted that while
In some examples, the one or more lines can include a looped line comprising a feed portion 108 and a return portion 110. The feed portion 108 can be guided downhole via a winding drum 112 and the line guidance support 116. The return portion 110 can be guided up hole via the line guidance support 116 and a return drum 114.
In some examples, the hydraulic subsystem 202 can have an engaged mode and a disengaged mode. In the engaged mode, the hydraulic subsystem 202 can be powered by the pulley assembly 200. The pulley assembly 200 can include a pulley wheel 206. The feed portion 108 and the return portion 110 of the one or more lines (e.g., looped slick line) can be slidably engaged to the pulley wheel 206. As the return portion 110 is pulled up hole by the line power subsystem 102, the pulley wheel 206 can be rotated. as the pulley wheel 206 rotates, the mechanical energy generated by the pulley wheel 206 can be operable to power the hydraulic subsystem 202. (e.g., engaged mode). In the disengaged mode, the feed portion 108 of the one or more lines can be used to position tools downhole towards the geothermal wellbore tractor 104, without causing the geothermal wellbore tractor 104 to move.
the hydraulic subsystem 202 can be operable to provide power to the plurality of wheels 118(a), 118(b), 118(c), 118(d) to cause the plurality of wheels to rotate, thereby moving the geothermal wellbore tractor 104 through the geothermal wellbore. The hydraulic system can include a high pressure reservoir, a low pressure reservoir, and a mechanism to allow fluid movement between the high pressure and low pressure reservoirs. The low pressure reservoir can have a lower pressure than the high pressure reservoir. Further the hydraulic system can include a mechanism to produce usable work from movement of such fluid, for example, one or more pistons or turbines as nonlimiting examples. The fluid of such hydraulic system may benefit from large expansion coefficients including thermal expansion coefficients and compressibility. In operation, for example, in the engaged mode, rotation of the pulley wheel 206 translates power through the hydraulic subsystem to the plurality of wheels 118(a), 118(b), 118(c), 118(d). As the pulley wheel 206 rotates, the hydraulic subsystem 202 can cause the plurality of wheels 118(a), 118(b), 118(c), 118(d) to rotate or cause other propulsion mechanisms to initiate. In this manner, motion of the geothermal wellbore tractor 104 can be controlled via the feed portion 108 of the one or more lines (e.g., slick line). Although a hydraulic system is desirable, other direct gearing mechanisms of work transmission are possible.
In some examples, the geothermal wellbore tractor 104 can include a mechanical governor. The mechanical governor can control the rotation rate of the plurality of wheels 118(a), 118(b), 118(c), 118(d) such that the movement of the geothermal wellbore tractor 104 is controlled. By controlling the rotation rate of the plurality of wheels 118(a), 118(b), 118(c), 118(d) the speed of the geothermal wellbore tractor 104 can be controlled, thereby ensuring smooth and controlled movement within the wellbore.
In some examples, the one or more lines can be operable to control the motion of the geothermal wellbore tractor 104 and/or control actuation of the anchor 204. For example, when the one or more lines are operating in a forward direction (e.g., feed portion 108 moving towards the geothermal wellbore tractor 104), the hydraulic subsystem 202 can cause the plurality of wheels 118(a), 118(b), 118(c), 118(d) to rotate in a forward direction. When the one or more lines are operating in a reverse direction (e.g., feed portion 108 moving away from the geothermal wellbore tractor 104), the hydraulic subsystem 202 can cause the wheels 118(a), 118(b), 118(c), 118(d) to rotate in a reverse direction (e.g., towards a vertical portion of the geothermal wellbore). The one or more lines may be operated with tugs (e.g., a pull with respect to the tractor). The sequence of the tugs, duration of the tugs, amplitude off the tugs, or combination therein may actuate mechanical positions of the tractor to complete tasks of the tractor such as achieving motion at various speeds, stopping, speeding up or down, or anchoring, or powering the hydraulic or mechanical system as nonlimiting examples.
The one or more lines can also be operable to control the actuation of the anchor 204. For example, a certain procedure (e.g., pattern of forward and reverse motion of the one or more lines) can be used to cause the anchor 204 to anchor to the geothermal wellbore, thereby fixing the geothermal wellbore tractor 104 in place. Similarly, a certain procedure (e.g., pattern of forward and reverse motion of the one or more lines) can be used to cause the anchor 204 to released from an anchored position to an unanchored position, thereby allowing for tractor motion. For example, reversing the direction of motion of the one or more lines can engage or disengage the anchor 204.
The motion of the one or more lines can also provide additional control commands to the geothermal wellbore tractor 104. For example, specific commands can be transmitted to the geothermal wellbore tractor 104 by alternating motion sequences (e.g., loop sequences when the one or more lines include a looped line) between forward and backward movements over set distances. Using the one or more lines motion to transmit commands allows for control over the geothermal wellbore tractor 104 operation without relying on complex electronic communication systems.
In some examples, the geothermal wellbore tractor 104 includes one or more electronic components. Such electronics may be digital or analog. Generally low power analog electronics are more suitable for high temperature operation, however some flashing may allow digital components to be utilized. The one or more electronic components can include sensors, controllers, and/or other electronic components operable to accurately locate and control the geothermal wellbore tractor 104. In some examples, the one or more electronic components can include high-temperature sensors and analog electronics configured to operate at very low power levels to ensure minimal heat generation and maintain system integrity. In some examples, the one or more electronic components can be powered by the hydraulic subsystem 202. The geothermal wellbore tractor 104 can include a generator and/or alternator. The generator and/or alternator can be operable to siphon off a portion of the hydraulic power generated in the hydraulic subsystem 202. The generator and/or alternator can convert the hydraulic power to electrical energy for powering the one or more electronic components. The use of the hydraulic subsystem 202 or mechanical system to power the one or more electronic components allows for functionality of the one or more electronic components without compromising the thermal resilience of the geothermal wellbore tractor 104.
In some examples, the one or more electronic components can include electromagnetic sensors configured to count casing collars. For example, the electromagnetic sensors can count each casing collar as the geothermal wellbore tractor 104 moves through the wellbore. In this manner, the location of the geothermal wellbore tractor can be determined.
The one or more lines can also be used to provide location and status information of the geothermal wellbore tractor 104. Tension in the one or more lines can be measured. For example, when the one or more lines includes a looped line, the tension on the looped line at the surface can provide status and operation conditions of the geothermal wellbore tractor. In some examples, the tension on the looped line and the length of looped line used to position the geothermal wellbore tractor 104 can be converted into location information. For example, when a known length of the looped line is used to position the geothermal wellbore tractor 104, the location of the geothermal wellbore tractor 104 within a horizontal wellbore can be calculated.
In some examples, the geothermal wellbore tractor 104 can include a mechanical energy system. The mechanical energy system can be in addition to, or an alternative of, the hydraulic subsystem 202. In some examples, the mechanical energy system can be a direct drive mechanical energy system. The mechanical energy system can include a gear system. The gear system can be operable to convert the mechanical energy from the one or more lines (e.g., slick line), via the line attachment mechanism (e.g., pulley assembly 200), directly into motion of the plurality of wheels 118(a), 118(b), 118(c), 118(d). For example, as the one or more lines (e.g., slick line) rotate the pulley wheel 206, the pulley wheel 206 can translate power to the gear system, which in turn causes the plurality of wheels 118(a), 118(b), 118(c), 118(d) to rotate. In some examples, hydraulic power from the hydraulic subsystem 202 can be less effective than mechanical power. The mechanical energy system can be operable to provide an alternative form of power to control the motion of the geothermal wellbore tractor 104.
In some examples, the one or more lines can be interchangeable. Once the geothermal wellbore tractor 104 is anchored into position (e.g., via the anchor 204), the one or more lines can be gradually increased to higher strength lines. When the one or more lines include a looped slick line, higher strength lines can be incrementally positioned. For example, the feed portion 108 of the one or more lines can be attached to a higher strength slick line. The higher strength slick line can then be run down through the pulley assembly 200 and back up to the line power subsystem 102. This process can be repeated until a high strength slick line and/or wireline is in place within the pulley assembly 200. The final high strength slick line and/or wireline can be of sufficient strength to pull wireline tools and/or the geothermal wellbore tractor 104. By gradually increasing the line strength, the risk of failure of the line is reduced. Further, the final slick line and/or wireline has sufficient strength to manage the weight and friction associated with the tool string. In this manner, operators can efficiently and safely position tools (e.g., wireline tools) in the horizontal section of the well, thereby facilitating effective logging and well integrity assessment.
The final slickline and/or wireline can be operable to locate one or more tools within the wellbore. In some examples, the one or more tools can be one or more wireline tools. In some examples, the one or more tools can include a water hammer, an azimuthal cement bond evaluation system, or other tools for logging and well integrity evaluation. In some examples, the transit time of the one or more tools to the geothermal wellbore tractor 104 can be used to provide location data for the geothermal wellbore tractor. For example, when the one or more tools are traveling at a known speed and the transit time to the geothermal wellbore tractor is measured, the location of the geothermal wellbore tractor 104 can be determined.
In some examples, the final slickline and/or wireline can be locked into position with the geothermal wellbore tractor 104. For example, once the tractor is anchored (e.g., via anchor 204), and the proper strength slickline and/or wireline has been used to properly locate the tool string in the geothermal wellbore, the slickline and/or wireline can be locked into position with the geothermal wellbore tractor 104. In some examples, the slickline and/or wireline can be locked into position via a mechanical locking mechanism and/or an electronic locking mechanism. Locking the final slickline and/or wireline into position can cause the hydraulic subsystem 202 to enter one or more additional modes. For example, when the final slickline and/or wireline is locked into position with the geothermal wellbore tractor 104, the geothermal wellbore tractor 104 can enter the disengaged mode, allowing the geothermal wellbore tractor 104 to remain stationary while other operations are conducted including powering the hydraulic system.
In some examples, the one or more additional modes can include a reverse mode. In the reverse mode, the geothermal wellbore tractor 104 can be dragged along the wellbore by the final slick line and/or wireline, thereby causing the plurality of wheels 118(a), 118(b), 118(c), 118(d) to rotate. The reverse mode can be used when the geothermal wellbore tractor 104 is being pulled out of the wellbore. For example, when the geothermal wellbore tractor 104 is located at an end of a horizontal portion of a wellbore (e.g., distal to a vertical portion of the wellbore), the geothermal wellbore tractor 104 can be placed in the reverse mode and dragged along the horizontal portion of the wellbore towards the vertical portion of the wellbore, thereby rotating the plurality of wheels 118(a), 118(b), 118(c), 118(d). As the plurality of wheels 118(a), 118(b), 118(c), 118(d) rotate, power can be generated in the hydraulic subsystem 202 or mechanical subsystem. In this manner, for example hydraulic power can be generated as the geothermal wellbore tractor 104 is being pulled out of the wellbore. The hydraulic power can then be used to power one or more tools of the tool string, thereby allowing the tools to conduct operations within the wellbore. Additionally, the hydraulic power can be used to power the one or more electronic components described herein.
In some examples, the one or more tools can include one or more azimuthal inspection tools. For example, the one or more azimuthal inspection tools can include an azimuthal cement bond evaluation system, an azimuthal casing inspection tool, or other azimuthal tools. The one or more azimuthal inspection tools can include a rotating section powered by a motor. Typically, azimuthal inspection tools require significant power. For example, the motor can be a 600-watt motor. The motor control, associated with electronics, and the heat generated during operation pose significant challenges similar to those encountered by standard wellbore tractors, especially in high temperature environments. By using the hydraulic power generated by the plurality of wheels 118(a), 118(b), 118(c), 118(d) as the geothermal wellbore tractor 104 is pulled through the wellbore, these issues can be mitigated. The hydraulic subsystem 202 can drive the rotating section, eliminating the need for high-power electronics and reducing heat generation, thereby providing reliable and efficient operation of the one or more azimuthal inspection tools under extreme conditions associated with geothermal wells and ensuring accurate and effective well integrity assessments. Such configuration benefits from a hydraulic or mechanical power line throughout the string of equipment that may be used for powering such equipment in a non-electrical fashion. Non limiting examples of mechanical power system include a rotating shaft, or rotating chain. Such rotating shaft may be flexible or contain segmented joints.
In some examples, the mechanical governor described herein, or another mechanical governor, can also be operable to control the rotation rate of the one or more azimuthal inspection tools. The mechanical governor can ensure that the rotation rate of the rotating section of the one or more azimuthal inspection tools remains constant. The constant rotation rate allows for precise and accurate measurements of cement bonds, casing integrity, and/or other measurements made by the one or more azimuthal inspection tools.
In some examples, the geothermal wellbore tractor system 100 can further include one or more generators powered by the one or more lines and/or the reverse rotation of the plurality of wheels 118(a), 118(b), 118(c), 118(d). For example, each tool on a tool string can include a generator and/or pulley assembly 200. As the one or more lines rotate the pulley wheel 206, hydraulic power can be used to power each of the generators. In this manner, the generators can power each tool in the tool string. Additionally, the reverse rotation of the plurality of wheels 118(a), 118(b), 118(c), 118(d), can be used to power the hydraulic subsystem 202 which can be used to power the one or more generators. In some examples, the generators use the hydraulic power directly to control motion of the one or more tools. In some examples, the generators can be operable to convert the hydraulic power to electric power for operating the one or more tools.
In some examples, the one or more lines can be operable to power the geothermal wellbore tractor 104 in a push system. In this example, the geothermal wellbore tractor 104 is positioned at the head of the tool string. The one or more lines can include the looped slick line, and similar to the above system, the looped slick line can power the hydraulic subsystem 202 to provide control over movement of the geothermal wellbore tractor 104. The push system can reduce the tension on the looped slick line.
In some examples, the one or more lines can include a terminating single slick line rather than a looped line. In this example, the single slick line is operable to alternatively pull and release a pumping mechanism attached to the geothermal wellbore tractor 104. The pumping mechanism can be attached to the single slick line via a line attachment of the geothermal wellbore tractor 104. In some examples, the geothermal wellbore tractor 104 is anchored by the anchor 204 as the slickline alternatively pulls and releases the pumping mechanism. The pumping mechanism can be operable to charge the hydraulic subsystem 202. In some examples, the slick line action can intermittently or continuously charge the hydraulic subsystem 202 via the pumping mechanism. The hydraulic subsystem 202 can then be used to control the motion of the plurality of wheels 118(a), 118(b), 118(c), 118(d) and/or the tools in the tool string, as described herein.
Regardless of the configuration of the one or more lines, accurate control of the one or more lines at the surface is required for operating the geothermal wellbore tractor 104 and/or utilizing the geothermal wellbore tractor 104 as a generator for hydraulic and/or electric power. To control the one or more lines, and thereby the geothermal wellbore tractor 104, tension and positioning of the one or more lines can be monitored. For example, the winding drum 112 is operable to release the one or more lines at a faster rate than the return drum 114 to compensate for increased distance as the geothermal wellbore tractor 104 moves further into the wellbore. Similarly, when the geothermal wellbore tractor 104 is being pulled back to the surface, the return drum 114 pulls the one or more lines at a faster rate than the winding drum 112 releases the one or more lines.
One- or two-way communication between the geothermal wellbore tractor 104 and the operator at the surface can be accomplished using the tension in the wire (e.g., as described herein) and with other communication methods. In some examples, the one or more lines can be e-lines (e.g., having a single conductor). In some examples, pulsed telemetry can be used to enable two-way communication between the geothermal wellbore tractor 104 and the operator at the surface. In some examples, optical telemetry can be used to enable two-way communication between the geothermal wellbore tractor 104 and the operator at the surface. The geothermal wellbore tractor 104 can position a reflector for water hammer communication with the position of the reflector changing the nature of the water hammer reflection such that information is conveyed to surface with minimal power consumption of the geothermal wellbore tractor 104. Alternatively, the tractor may drag a fiber optic with modulation of the fiber optic performed downhole by the geothermal wellbore tractor 104 and the power source for the fiber optic at surface. In other examples, the tractor may use the slick line to provide a conduit for communication by electrical, optical, or mechanical means. Modulation may be accomplished mechanically, acoustically, electrically or magnetically. Such modulation may be digital or analog in both modulation form and in transmitted information, or a combination therein.
In some examples, when pulsed telemetry is used to enable two way communication, pulse signals can communicate control commands to the geothermal wellbore tractor 104 and receive feedback from the geothermal wellbore tractor 104, providing a method for data transmission. Pulsed telemetry can be configured to withstand high temperatures, ensuring reliable communication in geothermal wells. Pulsed telemetry can also have low power requirements to operate, reducing heat generation and enhancing efficiency.
In some examples, the e-line can combine power delivery and data communication though a single conductor. The e-line can provide a high data transmission rate compared to traditional mechanical or pulsed methods. The e-line can be adapted for high-temperature environments using appropriate insulation.
In some examples, optical telemetry can be used to enable two way communication between the geothermal wellbore tractor 104 and an operator at the surface. Geothermal wells are typically brine-filled and somewhat clear. Optical telemetry can be achieved using high-temperature flash optics (e.g., xenon flash). Optical telemetry can provide high data transmission rates, suitable for complex data requirements of the one or more tools. In some examples, optical telemetry can be accomplished using high-temperature tolerant materials, such as xenon flash. Optical telemetry can provide accurate positioning and operational data of the geothermal wellbore tractor 104 and the one or more tools. Alternatively, the optical transmission may use modulation or reflection of surface optical signals.
The chemical steam system 400 can include a first chamber 402, a second chamber 404, a low-pressure line 406, a high-pressure line 408, a steam engine 410, the hydraulic subsystem 202, and an electric generator 412. The second chamber 404 can surround the first chamber 402. The first chamber 402 can be operable to contain a first compound. The second chamber 404 can be operable to contain a second compound. The first compound can be operable to exothermically react with the second compound, thereby producing steam. The steam can flow through the high-pressure line 408 and drive the steam engine 410. As the steam engine 410 is driven, hydraulic power can be generated and power the hydraulic subsystem 202. In this manner, the hydraulic subsystem 202 can provide the hydraulic power needed to perform the various functions described herein. As described herein, the electric generator 412 can be operable to convert the hydraulic power in the hydraulic subsystem 202 into electric power for powering the one or more electronic components of the geothermal wellbore tractor 104 and/or the electronic components of the one or more tools.
In some examples, the first compound is water, and the second compound is barium oxide. The second chamber 404 can be a reaction chamber containing the barium oxide. The second chamber 404 surrounds the first chamber 402 which contains the water. The exothermic reaction between barium oxide and water heats the water above ambient temperature, producing steam at high pressures. The high-pressure steam can then drive the steam engine 410 to generate hydraulic power for the hydraulic subsystem 202. The exothermic reaction eliminates the need for external heating sources. As the steam is produced, it reacts with the barium oxide, maintaining a controlled pressure within the chemical steam system 400. The continuous steam generation cycle ensures reliable and efficient hydraulic power generation.
In some examples, the first compound can include water, ammonia, and/or formic acid. The second compound can include barium oxide, calcium sulfate, calcium oxide, magnesium oxide, phosphorous pentoxide, silicon tetrachloride, sulfur trioxide, aluminum chloride, and/or zinc chloride.
In some examples, the chemical steam system 400 utilizes reactions that produce condensed phase products from precursors (e.g., second compounds contained in the second chamber 404), such as calcium sulfate, calcium oxide, magnesium oxide, phosphorous pentoxide, silicon tetrachloride, sulfur trioxide, aluminum chloride, and zinc chloride, which offers a viable alternative for high-pressure steam generation and hydraulic power production. These chemicals react exothermically with water, generating significant heat and forming stable condensed phases, such as hydrates or other solid compounds. The reaction allows for efficient steam production without the need for external cooling systems to condense the steam, as the steam is chemically absorbed or reacted away. For example, calcium sulfate reacts with water to form gypsum, while calcium oxide forms calcium hydroxide. Similarly, magnesium oxide and phosphorus pentoxide form magnesium hydroxide and phosphoric acid, respectively. These reactions generate the necessary heat to produce high-pressure steam and also maintain manageable pressure levels within the chemical steam system 400.
In other examples, the first compound can be liquid ammonia and the second compound (e.g., precursor) can be hydrogen chloride, which produces high-pressure steam via exothermic reactions and produces condensed ammonium chloride. In another example, the first compound can be liquid formic acid and the second compound (e.g., precursor) can be sodium hydroxide, which produces high-pressure steam via exothermic reactions and produces condensed sodium formate and sodium bicarbonate. In some embodiments the first compound may be obtained from the wellbore environment such as water drawn from a water based drilling fluid.
With reference to
The anchored pulley-based deployment system 500 is configured to establish a cable loop to the surface via the slickline 532 and the pulley collar 510 to enable efficient and accurate logging operations through faster deployment and retrieval of logging and wellbore operation tools, particularly in horizontal and high temperature wells. The anchored pulley-based deployment system 500 minimizes operational delays, reduces tool exposure to high temperatures, and permits flask-type logging tool usage for improved thermal management. A flask-type logging tool is a downhole instrument built inside a thermally insulated pressure vessel, which may be vacuum sealed to protect sensitive electronics from high temperatures deep in the wellbore. In aspects, the anchored pulley-based deployment system 500 enables advanced depth-measurement techniques using tension and rotation sensors and cable markings; automated proximity-based cable-detachment sensors integrated into anchors for permanent reservoir monitoring; deployment methods using powered torpedoes or production-flow-driven cable injection; and improved logging accuracy, reliability, and efficiency.
Although the cable loop established by the pulley-based deployment system 500 is described as a slickline or wireline in some examples, it will be appreciated that the cable loop described herein can include other types of cables. For example, the cable loop can include composite cables, e-lines, fiber optic cables, and other types of cables used in wellbore drilling and/or logging. In some examples, e-lines can include conductors.
The anchored pulley-based deployment system 500 may be deployed, for example, from a drill string such as a logging-while-drilling (LWD) bottom hole assembly (BHA). The pulley collar 510 may be deployed from the drill string directly to the bottom of the wellbore. The pulley collar 510 may be integrated into the drill string and transported seamlessly during the drilling operation to the target depth within the horizontal section. The pulley collar 510 is coupled to an end of the anchor 520. In aspects, the anchor 520 may include its own drill or form a portion of the drill string. The anchor 520 may be configured to drill into a sidewall of the wellbore 14, and/or may be configured to drill further downhole into the wellbore to increase the wellbore depth or length.
Upon reaching a targeted well depth, the anchor 520 detaches from the drill string (e.g., as part of a LWD BHA) and securely anchors itself by drilling into the side wall of the wellbore. The targeted well depth can include a bottom of the wellbore, a side pocket of the wellbore (e.g., as described further herein), a target horizontal section of the wellbore, or any target location along depth of the wellbore. As illustrated in
The pulley collar 510 is anchored into a desired position via the anchor 520. The anchor 520 may be initially housed within the LWD BHA and deployed directly into the wellbore at a controlled angle using a drilling rotation and applied weight of the anchor 520. Once adequately embedded in the wellbore, the anchor 520 maintains the pulley collar 510 at a set position, e.g., via a rigid link 512, providing a robust and secure anchor point. The link 512 may be extendable and operable to deploy the pulley collar 510 from the anchor 520. In aspects, the drill string may be first retracted a short distance, clearing the position of the pulley collar 510 and/or the anchor 520. Following the retraction of the drill string, the pulley collar 510 is operable to be extended or deployed into the open wellbore from the anchor 520 via the link 512, thereby deploying the pulley assembly 562.
The slickline 532 is configured to form the loop to minimize friction and ensure efficient operation. In aspects, the slickline 532 may be deployed from the slickline spool 530 via a side-channel release adjacent to the slickline spool 530 or an internal deployment passing directly through the slickline spool 530. A dedicated mechanical or hydraulic guide integrated within the drill string ensures safe and controlled passage of the slickline 532 past the anchor 520, pulley collar 510, pulley assembly 562, and/or slickline spool 530, eliminating risks of entanglement, damage, or interference during the drill string's withdrawal. The robust and carefully managed anchoring and deployment strategy enhances reliability, simplifies the operational process, and significantly reduces the risk profile associated with horizontal open-hole logging operations.
As illustrated in
The pulley collar 510 can be transported and positioned by the anchor 520 via an LWD BHA during the normal drilling operation, thereby requiring minimal additional deployment time beyond the initial drilling process. Furthermore, the loop system enables wireline logging tools and/or wellbore tractors to be deployed to the wellbore, ensuring high-quality logging data, robust telemetry, and power capabilities, effectively mitigating the limitations associated with existing methods such as LWD, pipe-conveyed, ultra-slim, or prior tractor-based logging systems. By seamlessly integrating drilling and logging operations into one efficient process, the pulley-based deployment system 500 substantially enhances logging speed, reliability, and overall data quality for horizontal and vertical open-hole wells.
With reference to
As above, following anchor 556 deployment, the double-loop slickline is progressively unspooled from a dedicated spool 570 within a BHA as a drill string is withdrawn to the surface. The deployment of the double-loop slickline is carefully managed to prevent entanglement or abrasion of the slickline 574. An internal guide mechanism within the BHA or specialized bit ensures smooth and safe passage of the slickline through the bit opening, mitigating potential damage and ensuring operational integrity. By utilizing a specialized bit configuration, ultra-slim deployment tools and methods may be used with the same efficiency as other logging tools.
In through-bit deployment, the anchor 566 for the pulley collar can be secured via multiple methods and systems depending on operational requirements and formation conditions. In aspects, the anchor 566 is an ultra-slim anchor device that is hydraulically or mechanically expanded upon exiting a drill bit of the LWD BHA, establishing direct and secure contact with the formation wall, ensuring stability through direct frictional engagement. In aspects, the anchor 566 may be actively drilled into the formation at the bottom of the hole, embedding itself firmly into the subsurface through controlled rotational and downward force applied from the Bottom Hole Assembly (BHA). The drilling-anchor method described herein offers enhanced security and stability, particularly beneficial in softer formations or scenarios demanding exceptional anchoring reliability.
With continued reference to
The slickline 532 used for conveying logging tools (e.g., logging tool 550) in the pulley-based deployment system 500 may be configured to be pre-attached to the pulley collar 510. As the anchor 520 is deployed—whether through drilling into the formation or via hydraulic or mechanical expansion—the slickline unspools seamlessly from a dedicated spool within the BHA, simplifying operations by ensuring immediate readiness upon anchor deployment.
In aspects, the slickline 532 can be attached separately in a subsequent operation after the anchor 520 and pulley collar 510 are deployed and securely anchored in place. In such aspects, once the BHA is withdrawn to the surface, the slickline 532 is manually attached at the surface and deployed downhole to interface with the already installed anchor 520 and pulley assembly 562. Such aspects provide operational flexibility, allowing for inspection, confirmation of anchor integrity, and/or maintenance before attaching the slickline.
In aspects, the slickline spool 530 itself is integrated directly into the pulley collar 510. In such aspects, the slickline spool 530 remains anchored downhole alongside the pulley system. As the drill string is withdrawn to the surface, via drill string line 560, it automatically draws the slickline upward from the stationary, downhole slickline spool 530, creating the double-loop configuration extending to surface. Such aspects reduce complexity at surface, as no separate surface-side spool management is required during withdrawal. Additionally, maintaining the spool downhole protects the slickline during deployment and limits exposure to potential mechanical damage during the withdrawal process, enhancing the reliability and simplicity of slickline deployment and subsequent logging operations.
In more aspects, the slickline 532 and pulley collar 510 can be deployed independently of the initial drill string operation through a pumped-down deployment. For example, the pumped-down deployment can include a pump mechanism configured to pump fluid into the wellbore. For example, the pump mechanism can include a surface pump and/or downhole pumps operable to control the flow and/or pressure of fluid flowing in the wellbore. The pump mechanism can provide fluid to the wellbore and/or control fluid flow of fluid already in the wellbore. The fluid (e.g., pressurized fluid) can carry the slickline 532 and pulley collar 510 downhole. For example, the pump mechanism can be operable to control the pressure of the fluid, thereby controlling the movement of the slickline 532 and the pulley collar 510 within the wellbore. After the anchor 520 is securely deployed and set downhole, the pulley collar 510 (e.g., including the pulley assembly 562) along with the slickline 532 or a conventional wireline is pumped down separately. Upon reaching the anchor 520, the slickline or wireline establishes a reliable electrical or mechanical wet-connect interface with the anchor 520 and pulley collar 510. The method expands operational flexibility, as the space constraints associated with housing a spool within the BHA are mitigated. For example, larger-diameter conventional wirelines with higher data rates and improved logging capabilities may be utilized without the size constraints conventionally imposed by requiring a spool or conventional wireline to be carried downhole by the drill string. For example, the slickline spool 530 and/or the conventional wireline can be pumped downhole after initial drilling. The pumped-down approach, combined with a robust downhole wet-connect mechanism, optimizes logging efficiency, enhances data quality, and reduces operational complexity in horizontal open-hole logging operations.
In yet more aspects, the slickline 532—deployed by any of the methods described herein—may serve as a dedicated conveyance mechanism to subsequently pull a conventional wireline into the downhole pulley position. In this scenario, after establishment of the slickline loop to the pulley collar 510, operators can attach a standard-sized, conventional wireline logging cable to one end of the slickline at the surface. By spooling in the slickline 532 from the surface, the conventional wireline is smoothly drawn downhole into logging position at the anchored pulley location. While the method involves additional time and operational steps due to the sequential, double deployment process, the method provides significant advantages by eliminating the need for pumping conventional wireline, thereby reducing mechanical complexity and potential damage risks associated with high-flow pump-down operations. Consequently, operators benefit from the enhanced data acquisition capabilities, telemetry, and power availability of conventional wireline logging tools without the constraints or complications associated with direct pump-down deployment methods.
In aspects, a drill bit portion of the BHA is operable to detach from a primary BHA section, leaving behind an integrated anchor and pulley collar in the borehole. The pulley collar 510 and anchor 520 remain directly attached to or integrated with the detached drill bit. A conventional hydraulic or mechanical anchoring mechanism may secure the assembly (e.g., pulley collar 510 and anchor 520) firmly against the borehole wall.
After completing wireline logging, the anchor 520 may release from its position in the wellbore via a mechanical or hydraulic driver configured to release the anchor 520 by reverse drilling or otherwise releasing the anchor 520. By releasing the anchor 520 and any connected components, the anchor 520, the pulley collar 510, and the slickline 532 may be recovered along with, or after, retrieval of the logging tools to the surface. Recovery of the anchor 520, pulley collar 510, and any associated drill bit reduces operational costs, minimizes equipment loss, and maintains efficient resource utilization throughout the logging and drilling process.
As illustrated in
Once the wireline logging tool 550 reaches a desired downhole position, the bottom-end attachment can be selectively released, thereby allowing operators to pull the slickline 532 or wireline fully past the upper end of the wireline logging tool 550. Selectively releasing the wireline logging tool 550 ensures the slickline 532 or wireline does not remain stretched along the length of the logging tool during logging operations, eliminating potential interference with tool sensors, measurements, and/or mechanical components. After completion of logging operations, the top attachment is then utilized to pull the logging tool efficiently back to the surface, maximizing wireline logging tool 550 versatility, optimizes data integrity, and provides enhanced operational control within complex horizontal logging scenarios.
In aspects, a conventional wireline logging tool 550 may be pre-attached at a head end to a conventional wireline or slickline prior to deployment via a detachment mechanism 552. The detachment mechanism 552 may be located at a head end, a bottom end, or both, of the wireline logging tool 550. The wireline logging tool 550 may initially by conveyed downhole by a separate slickline attached to its downhole end, which pulls the assembly smoothly into the target logging position at the bottom of the horizontal wellbore. Upon reaching the desired depth, the downhole slickline attachment is selectively released via the detachment mechanism 552, freeing the wireline logging tool 550 from its downward conveyance mechanism. The separate slickline is then independently retrieved to the surface, leaving the wireline logging tool 550 secured in position at depth and connected only by its original wireline or slickline attached at its head. Afterward, standard logging operations proceed normally using the wireline or slickline at the wireline logging tool's head, enabling high-quality data acquisition without interference from additional deployment lines. The detachment mechanism 552 provides simplicity and reliability, reducing complexity and eliminating operational risks associated with retaining multiple deployment lines downhole during logging activities.
In aspects, the detachment of the downhole deployment line (slickline or wireline) from the logging tool is automated based upon the proximity of the wireline logging tool 550 to the anchored pulley collar 510. Automatic release may be achieved via electrical signaling, mechanical triggers, or sonde-based control systems, or other mechanisms for determining a location of the wireline logging tool 550 relative to the pulley collar 510. Additionally, an algorithmic control approach may be implemented, wherein embedded sensors in the wireline logging tool 550 or pulley collar 510 continuously monitor the relative positioning and proximity between components, triggering detachment when predetermined spatial conditions are met. The release may also be manually controlled from the surface.
In aspects, a lightweight slickline or even a lighter preliminary line may initially be deployed using a specialized torpedo system. The specialized torpedo system is configured for horizontal conveyance in open-hole wellbores and may possess neutral or controlled buoyancy to optimize downhole navigation and minimize frictional interactions. Propulsion for the specialized torpedo may be provided through battery-powered electric jet systems or propeller-driven mechanisms, though chemically driven propulsion methods may alternatively be employed. As the specialized torpedo travels along the wellbore, the specialized torpedo deploys or trails the lightweight slickline or preliminary line, either from an internal spool within the torpedo itself or from surface-mounted deployment equipment.
Once the initial lightweight slickline is successfully positioned, progressively heavier and stronger lines—including conventional wirelines suitable for logging operations—can subsequently be pulled into place by using the initial lightweight line. The present disclosure provides a staged deployment approach that ensures reliable conveyance of logging-grade lines into complex horizontal trajectories. The lightweight slickline may be deployed after retrieval of the BHA or drill string. The specialized torpedo deployment method provides enhanced operational flexibility, improved line placement efficiency, and/or adaptability to a range of downhole environments and operational conditions.
The pulley-based deployment systems described herein provide a significant operational advantage by enabling effective thermal mitigation strategies, such as cooling and flasking, which are not feasible with other horizontal logging deployment approaches. The pulley-based deployment systems described herein enhance the effectiveness of flasking and cooling systems by reducing exposure times to the harsh environments in the wellbore and freeing up space in the space restricted wellbore. Since the pulley-based deployment systems significantly reduce operational time spent positioning wireline logging tools in horizontal sections of a wellbore—substantially decreasing thermal exposure duration—the efficacy and reliability of flasking and cooling systems are considerably enhanced. The decreased thermal exposure enhances horizontal logging applications, where prolonged downhole exposure frequently leads to increased thermal stresses and associated reliability issues. Consequently, the disclosed pulley-based deployment system significantly improves logging tool performance, reliability, and data quality, especially in high-temperature horizontal well environments. Further advantages of the pulley-based deployment systems of the present disclosure include the ability to use simpler logging tools and sensors outside a BHA drill string, rather than those produced using complex and costly methods to withstand sustained high-temperature environments.
In aspects, an additional advantage is the ability to determine accurate cable tension as the slickline or wireline elongates due to temperature changes down the wellbore. Since the slickline 532 is looped back to the surface, measurements may be taken at the surface, at logging tool, at the pulley collar 510, at the anchor 520, and back at the surface, and a detailed tension profile of the slickline 532 may be constructed along its length. The detailed tension profile can be directly correlated to cable elongation or contraction using known elasticity characteristics and temperature dependencies of the cable material, thereby providing corrections for depth inaccuracies typically induced by thermal expansion and mechanical stress. The ability to determine accurate cable tension mitigates through multiple points in the cable and back mitigates errors caused by elongation due to temperature variations and tension, friction-induced slack, differential sticking, and non-uniform borehole geometry. The pulley-based deployment system thus provides more accurate determination of positions relative to the Traditional Measurement While Drilling (MWD), Logging While Drilling (LWD), and wireline methods, which often struggle to provide a consistently precise depth reference, impacting the accuracy of formation evaluations and subsequent operational decisions.
The anchor 520, the pulley assembly 562, and/or the pulley collar 510 at the bottom of the hole itself may serve as a stable reference point for additional depth validation. Incorporating precision rotation counters on the pulley collar 510 allows direct measurement of the cable length traversing the pulley, providing an independent and stable depth reference point largely unaffected by surface conditions or intermediate borehole friction. By continuously comparing the pulley-based depth measurement with surface-based cable withdrawal measurements, operators can detect and quantitatively estimate discrepancies caused by cable elongation, slack, frictional resistance, or localized deformation effects. The comparison of the pulley-based depth measurement and surface-based cable withdrawal measurements enables real-time corrections of location data and tension data, enhancing depth measurement precision. In aspects, algorithms or machine learning-based models, informed by historical and real-time operational data, can further refine corrections dynamically, adjusting for specific well conditions and operational scenarios.
In aspects, to further enhance the accuracy and reliability of depth measurements, the pulley collar 510 and/or pulley assembly 562 may include integrated sensing capabilities designed to read optical and/or magnetic markings placed along the length of the cable (e.g., the slackline or wireline). The optical and/or magnetic markings, strategically positioned at known intervals, serve as absolute reference points to independently verify and refine depth measurements obtained through tension profiling and pulley rotation counting methods. Optical sensors (e.g., laser-based or camera-driven detection systems) or magnetic reading heads built into the pulley collar 510 and/or pulley assembly 562 can register the optical and/or magnetic markings, providing additional checkpoints to mitigate cumulative measurement errors. By combining the marking-derived reference points with the previously described real-time tension and rotation-based measurements, operators can achieve a robust, redundant, and highly accurate depth measurement system, significantly surpassing conventional depth tracking methods and substantially improving overall logging precision and operational efficiency.
In addition to facilitating efficient wireline deployment and precise depth measurement, the pulley anchor system can be further enhanced by integrating various downhole measurement sensors directly within its structure. The integrated sensors may include, but are not limited to, pressure sensors, temperature sensors, acoustic sensors, electromagnetic sensors, and other specialized formation evaluation devices. During normal logging operations, data from the integrated sensors can complement and enrich measurements obtained from conventional logging tools, providing additional real-time insights into formation and reservoir conditions. Furthermore, if operationally advantageous, the pulley anchor system can be configured for long-term permanent placement downhole. When the pulley anchor system is permanently placed downhole, the embedded sensors remain continuously in contact with the reservoir bottom, allowing operators to monitor reservoir parameters over extended periods. The permanent deployment of the pulley anchor system transforms the pulley anchor into a valuable reservoir-monitoring asset, capable of delivering ongoing pressure, temperature, acoustic, or electromagnetic data, significantly enhancing reservoir management, production optimization, and reservoir characterization efforts.
In aspects, a permanently deployed downhole pulley collar is provided for cased-hole applications. The pulley-based deployment system is installed permanently within the casing, either as part of the original well construction or retrofitted using a one-time deployment via tractor conveyance. A specialized slick line or e-line may be initially contained within the anchor or pulley collar and is configured to operate on minimally sufficient electrical power capabilities.
When logging or monitoring is required, the slick line or e-line is ejected into the well's production flow stream, allowing the natural production flow to carry it to the surface. Upon reaching the surface, the slick line or e-line utilizes its limited electrical power to activate a self-contained winding mechanism to recover and rewind itself, reestablishing a robust loop from surface to the permanently anchored pulley collar.
The slick line or e-line may include a torpedo assembly configured to facilitate reliable ascent through the production stream. The torpedo may be chemically powered for efficient propulsion, or, in aspects, utilize an electric drive system. Additionally, the torpedo may optionally feature a sail or similar passive aerodynamic device to enhance its upward journey by better harnessing the force of the production flow. Due to operational considerations and wear, the torpedo may be designed for replacement after each logging or monitoring operation before retraction by the e-line.
Upon reaching the surface, the slick line or e-line may be used to pull a stronger looped cable line into position and connect to the pulley collar. Logging tools can then be rapidly deployed into long completed cased-hole sections utilizing methods previously described. The permanently deployed pulley collar and e-line enables periodic reservoir evaluation operations.
With reference to
Each of the modular compartments 710 may define housings for tools or wellbore components to be selectively deployed in the wellbore to facilitate logging, maintenance, repairs, or upgrades without requiring retrieval of the modular tractor and logging system from its downhole location in the wellbore. The modular compartments 710 may include pressure-sealed compartments, each independently housing operational tools and/or modules. For example, each modular compartment may include pressure, temperature, acoustic, electromagnetic, nuclear, and optical sensors; fluid sampling or rock coring modules; computation units for real-time data processing; telemetry modules for data communication; and power modules including batteries or turbine-driven power packs. The modular compartments 710 may be interconnected via self-sealing wet-mate interfaces, enabling secure and efficient detachment and attachment downhole. In aspects, the modular compartments 710 may be selectively coupled, deployed, re-attached, and/or reordered using mechanical or hydraulic release mechanisms coupling each of the modular compartments 710 to the tractor body 702. The tractor body 702 may include a tractor channel for conveying any modular compartments 710 to an uphole or downhole end of the tractor body for retrieval or deployment of the modular compartments 710.
The modular compartments 710 may be selectively retrieved from a downhole wellbore position without retrieving the whole the modular tractor and logging system 700. Each modular compartment 710 may be passed through, deployed, or released from the tractor body 702. In aspects, each modular compartment 710 may be coupled to a slickline 730, (which may be slickline 532 or any other slickline or wireline), and retrieved to the surface for repair or replacement. In some aspects, the modular tractor and logging system 700 and/or each modular compartment 710 may be deployed into the wellbore or retrieved using pumping mechanisms. Advantageously, individually retrieving each modular compartment 710 enables the modular tractor and logging system 700 to continue other operations via the remaining modular compartments 710. For example, operationally, if internal diagnostics detect modular compartment mission failure or mission completion, such as sensor degradation, sample collection completion, or availability of technological upgrades, the specific modular compartment detaches through mechanical or hydraulic release mechanisms, ensuring the preservation of the tool's pressure integrity.
The detached modular compartment 710 may be retrieved to the surface using methods such as slickline, wireline, or pump-down techniques, which may be facilitated by the pulley-based deployment systems described herein. Once retrieved, a replacement modular compartment 710 containing new sensors, new sampling capabilities, upgraded computational or telemetry hardware, or replenished power supplies may be deployed from the surface. Alignment guides 740 ensure accurate mating, automatically engaging mechanical, hydraulic, and electrical connections securely. Alignment guides 740 may be physical structures within the modular tractor and logging system 700 operable to guide modular compartments 710 into place within the tractor body 702.
After installation of a modular compartment 710, an automated downhole self-check may be performed, for example, via the processing computing module 706, which verifies the modular compartment functionality and integration integrity, with data transmitted to surface control for confirmation. Modular replacement capability significantly enhances operational flexibility by enabling rapid repairs and upgrades without complete retrieval of a tool or the modular tractor and logging system, thereby minimizing downtime, operational costs, and rig time, especially valuable in deep, high-temperature, or high-pressure environments. Furthermore, modular replaceability promotes continuous optimization through swift adoption of technological advancements, extends equipment reliability and longevity, and improves efficiency in maintaining high-integrity sampling. Applications particularly benefiting from compartmentalized replacement may include, but are not limited to, permanent reservoir monitoring, fluid sampling operations, and operations in geothermal, harsh, or remote well environments.
In aspects, the modular compartments 710 may be provided in a dedicated, compartmentalized downhole tool system separate from the modular tractor and logging system 700. In aspects, a tractor can directly convey a modular compartment 710 from the downhole tool system to the surface and subsequently transport a replacement compartment back downhole. In aspects, the tractor may detach a modular compartment from the downhole tool assembly and then transfer it onto an independent conveyance system, such as a pulley-based line, torpedo conveyance, or spooled slickline, effectively streamlining operations. Additionally, the modular tractor and logging system may be an integrated tractor-conveyance assembly configured to operate in a mid-point configuration, positioned at an intermediate depth, from which it can simultaneously deploy pulley-lines both upwards to the surface and downwards toward the downhole assembly, facilitating efficient two-way conveyance operations. The integrated tractor-conveyance capability significantly enhances operational flexibility, reduces retrieval and deployment times, and minimizes complexity in managing downhole compartment replacements, particularly beneficial in extended-reach or complex horizontal wells.
To achieve additional efficiency, the tractor body 702 includes a tractor channel 720 for conveying modular compartments around or through the tractor assembly. In aspects, the tractor body 702 may be configured to enable a modular compartment 710 to be passed around an external part of the tractor body 702. In aspects, a dedicated side-channel or bypass route can facilitate compartment movement, minimizing interference with the modular tractor and logging systems main mission objective.
In aspects, a tractor may incorporate an adjacent compartment positioned opposite the retrieval point, enabling direct internal transfer of items—such as samples, electronic boards, or sensors—through pressure-sealed interfaces within the tractor body 702. In such aspects, the tractor body 702 is further configured to ensure fluid flow within the wellbore remains unobstructed during modular compartment transitions, preserving operational efficiency, minimizing turbulence or blockage risks, and maintaining overall tool integrity during the transfer operation.
Methods for operating the modular tractor and logging system 700 include governing the timing and manner of detachment and/or retrieval modular compartments 710 based on fluid flow, tractor location, or other ongoing wellbore operations conducted by the modular tractor and logging system 700 or operations at the surface. In aspects, automated workflows enhanced by artificial intelligence (AI), machine learning (ML), or generative AI (GenAI) may be implemented to improve timing and manner of detachment and/or retrieval of the modular compartments 710. Automated workflows are configured to dynamically evaluate sensor data, real-time operational conditions, or predictive maintenance insights to autonomously initiate module replacement precisely when needed. Once detachment of a modular compartment 710 is initiated, workflows carefully seal any open channels, move or position the compartment as required, and securely interface the module with the tractor system.
In aspects, a plurality of couplers 750 may each secure one modular compartment of the modular compartments 710. The couplers 750 may be magnetic releases, spring-loaded mechanisms, mechanical latches such as rotational or sliding latches, actuatable clips, pressure-sensitive release mechanisms, wet-mate connectors, and/or dissolvable materials that safely degrade under controlled conditions.
In aspects, the modular tractor and logging system 700 may include one or more retrieval mechanisms for selecting, carrying, detaching, or re-attaching the modular compartments 710 to the tractor body 702 or to a slickline 730 or other retrieval line or method (e.g., pumping, pulley-system described herein). The retrieval mechanism may include permanent magnetic catches, mechanical claws, hook and loop tape devices, electromagnetic catches, vacuum-based suction, other mechanical capture mechanisms, and/or chemical adhesives to firmly capture the modular compartment 710. Integrated sensors, such as optical or electrical sensors, precisely guide and position the detached modular compartments 710 during retrieval operations.
In aspects, the modular tractor and logging system 700 may strategically leverage downhole fluid flow, naturally guiding compartments into proper alignment within the tractor body 702 or downhole tool assembly, thereby enhancing retrieval reliability and minimizing operational complexity. Additional orientation control of a modular compartment 710 may be achieved using positioning mechanisms such as propellers, adjustable fins, chemical propulsion discharges, magnetic forces, pressure gradients, or electric potential gradients, precisely adjusting axial and yaw orientations. Additionally, optical or electrical sensors may accurately monitor and guide alignment of the modular compartments 710, and provide real-time positional feedback. In aspects, the advanced workflows interpret the sensing data, automatically adjusting positioning mechanisms until precise alignment is confirmed.
Once aligned, the modular compartments 710 may be anchored in position via the couplers 750, which may further include pressure-sealed interfaces, magnetic or electromagnetic coupling, environmentally activated or standard adhesives, mechanical claws, screw-type latches, or snap-fit latches. Sensing data produced by the sensors is continuously monitored through automated workflows to validate precise positioning and successful engagement of the coupling mechanism(s).
Power and communication between modules, the tractor body 702, and/or a downhole tool assembly may be established through either wireless transmission or wired wet-mate connectors. Wired wet-mate connectors, may employ specialized pins or plugs forming fluid-free sealed spaces prior to electrical or optical engagement. The wired wet-mate connectors may be configured to facilitate combined power and data transfer and may use power-over-ethernet for streamlined connectivity. Upon successful connection, automated workflows may initiate necessary firmware updates, software patches, or workflow enhancements, seamlessly integrating the installed modular compartments 710 into the existing downhole tool’s operational systems.
Further provided herein is a segmented pipeline pig system.
In aspects, each flexible tether 820 is configured to secure adjacent pig segments 810 and provide power and data communication between the pig segments 810.
The flexible tethers 820 may be adjusted dynamically to adjust a space between adjacent tethered pig segments 810. The length of each flexible tether 820 may be adjusted by winding or pulling on a portion of the flexible tether or releasing wound or pulled in portions of the flexible tether 820. In aspects, the flexible tethers 820 may include mechanical accordion mechanisms for adjusting the length of each flexible tether 820. Adjustment of the length of the flexible tethers 820 further enhances maneuverability of each pig segment 810. By adjusting the length of a flexible tether 820 dynamically, each pig segment 810 can be optimally positioned to achieve high-resolution data collection across pipeline segments.
Each pig segment 810 may include sensors dedicated to various diagnostic modalities, including acoustic, resistivity, magnetic, spectroscopic, optical, X-ray, or gamma ray technologies. A given pig segment 810 can carry either a specialized array of sensors or integrate multiple sensor types. Additionally, sensor capabilities can be strategically distributed across pig segments 810, enabling configurations such as a transmitter (TX) placed on one pig segment 810 with the corresponding receiver (RX) located on another pig segments 810, thereby enhancing sensing accuracy and operational flexibility.
Initial sensor data collected by leading pig segments 810 can guide precise adjustments of trailing pig segments 810. In aspects, the frequencies, pulse rates, amplitudes, phases, and/or axial positions of sensors on trailing segments can be dynamically modified based on real-time sensing feedback, and vice-versa. Such adaptability allows the multi-segmented pipeline pig 800 to concentrate increased resolution and enhanced detection capabilities precisely where pipeline deterioration (e.g., corrosion, erosion, or scaling) is historically or currently more prevalent.
To further enhance real-time monitoring and data retrieval capabilities, pig segments 810 can communicate wirelessly or via transient physical connections with permanently installed or temporarily placed pipeline-mounted data receivers and sensors. As each pig segment 810 passes the mounted data-receiving points, data can be transmitted instantaneously or buffered for later retrieval, enabling continuous real-time monitoring of pipeline conditions without interrupting production flows.
Incorporating advanced pressure monitoring, the multi-segmented pipeline pig 800 segmented pig system may include non-invasive pipeline pressure pulses. In aspects, one of the pig segments 810 may create controlled pressure pulses that may be detected by subsequent pig segments 810, enabling precise pressure profile measurements across pipeline sections. The pressure pulses can be passively sensed, actively amplified, and/or adjusted by successive segments as the pig segments 810 travel through the pipeline. Additionally, pig segments 810 can generate and transmit calibrated pressure pulses back to permanently installed pressure pulse receivers in the wellbore, offering enhanced diagnostic capabilities through precise pressure mapping along the pipeline.
In aspects, each pig segment 810 may include a modular compartment 710 that can be deployed or retrieved independently of the multi-segmented pipeline pig 800.
The integrated combination of modular segmentation, dynamically adjustable sensor spacing, advanced multi-modal sensor distribution, flexible data communication, and/or enhanced pressure pulse measurement significantly enhances pipeline diagnostic capabilities, thereby surpassing the resolution, reliability, and/or flexibility achievable by traditional pigging methods (e.g., pigging methods that only use a single pig).
The sensors 910 are configured for comprehensively measuring fluid properties. The sensors 910 may include pressure gauges, electrophoretic sensors, magnetic sensors, temperature sensors, and sensors capable of measuring viscosity, density, thermal conductivity, and electrical resistivity, spectroscopy sensors (for example, hyperspectral, ICE, multi-spectral, UV, VIS, IR, X-ray, THz, microwave, gamma, and/or neutron), nuclear magnetic resonance (NMR) sensors, and/or advanced electromagnetic sensors, for providing highly detailed real-time characterization of the flowing fluids.
Each sensor 910 may include one or more sensor types, or multiple sensors 910 may collaboratively measure properties with sensor outputs synergistically analyzed. Real-time adjustments are enabled by dynamically modifying sensor configurations or measurement settings in response to analysis of data collected by other sensing units via a processing unit in the wellbore or at the surface in communication with the sensors 910. The adaptive data-driven approach of the sensors 910 allows rapid identification and characterization of fluid composition changes, such as gas slugs or variations in oil-water-gas mixtures.
To ensure accurate and homogeneous fluid property measurements, the pipeline flow sensor system 900 may include one or more mixing mechanisms 920. The mixing mechanisms 920 may be actuated, active mixers, or passive mechanical mixers. Active mixers may employ rotating fins, impellers, or propellers that continuously mix fluid streams, simultaneously maintaining precise positioning against production flow. Alternatively, passive mechanical designs feature static or adjustable fins, with fin angles dynamically adjusted based on fluid composition to achieve optimal mixing.
The positioning and mobility of the sensors 910 may be achieved via any of the conveyance methods described herein (pulley-based deployment systems, modular tractor and logging system, or other conveyance systems) within the wellbore. Additional conveyance techniques include magnetically or electromagnetically driven treads (similar to tank tracks), wheels or rollers, adjustable-pressure suction-based attachments, and spatially adaptable radial gripping devices akin to a snake’s rib structure. Additionally, continuously operating propellers can stabilize sensor positioning against fluid flow while providing simultaneous mixing of fluids.
Integrated automated workflows leverage sensor-derived data to facilitate real-time ESP and production system adjustments. At the ESP level, sensor data informs dynamic control over valve apertures, pump rotational speeds, operational pressures, torque adjustments, and fluid intake optimization of the ESP, effectively mitigating negative impacts from gas slugs or rapid fluid changes. Concurrently at the surface, fluid streams are dynamically diverted into appropriate storage and processing pathways (e.g., separate lines for oil, gas, and water or waste streams) based on continuously monitored fluid property data, optimizing overall production efficiency and minimizing processing inefficiencies.
Additionally, to provide for faster and easier repair or replacement of an ESP, the present disclosure also provides a modular compartmentalized ESP 930. The modular compartmentalized ESP 930 enables targeted repair or replacement without retrieval of the whole ESP, substantially reducing downtime and operational costs. The ESP 930 comprises modular, independently compartmentalized modules 934, each housing specific ESP components, including motors, pump stages, sensors, control electronics, telemetry, or sealing mechanisms. If a module failure is detected via integrated diagnostics or changes in the fluid sensed by the sensors 910, or when a technological upgrade is available, specific compartments can be selectively detached while the remaining functional modules 934 remain installed and operational within the wellbore.
Using a tractor-based conveyance system deployed from the surface, such as the modular tractor and logging systems described herein, faulty or obsolete compartments are securely retrieved without removing the entire ESP system. Replacement modules are then delivered downhole, guided into alignment and secured using sophisticated alignment, sealing, and securing methods (e.g., magnetic coupling, mechanical latches, wet-mate connectors, environmentally responsive adhesives (as detailed in the compartmentalized replacements embodiment), and/or other suitable coupling mechanisms). The replacement modules can be aligned and installed in the ESP 930 using the systems and methods described herein.
Upon module replacement, power, data communications, and mechanical integrity are automatically re-established, utilizing wireless transmission or wired wet-connect interfaces capable of fluid-free sealing. The wireless transmission and/or wired wet-connect interfaces seamlessly integrate electrical, optical, and communication connections. Automated workflows subsequently trigger firmware updates, recalibrate control software, and integrate the new module into the operational control systems, enabling immediate resumption or enhancement of ESP functionality.
By combining advanced real-time sensing, adaptive fluid handling, modular compartmentalized ESPs 930, and tractor-based modular replacement, operational disruptions are reduced, fluid production is optimized, and/or maintenance downtime and associated operational costs in artificial lift deployments are decreased.
The wellbore tractor 1002 is deployable at the bottom of a wireline tool string. The wellbore tractor 1002 is configured to detach from the slickline spool 1006 and move independently of the slickline spool, while carrying a portion of the slickline as it unspools. The slickline spool may be located up hole of the tool string. The wellbore tractor 1002 may be configured as a small, speedy tractor because it does not need to carry the whole slickline spool 1006. The slickline spool 1006 may retract the slickline after the wellbore tractor 1002 anchors in a downhole position. As the slickline spool 1006 retracts the wire, the tool string advances toward the anchored wellbore tractor 1002 downhole. The motor 1004 may be configured to actuate the slickline spool 1006 to retract the slickline. The tread sections 1014 are configured to reduce friction between the tool string and the wellbore. The tread sections 1014 may include sled sections for reducing friction.
The wellbore tractor 1002 may be anchored into the wellbore via anchors 1020 which anchor into the wellbore wall. The anchors 1020 may include rods for puncturing through the wellbore formation or may be configured to pressure and/or friction fit the wellbore tractor 1002 against the wellbore walls. In aspects, the anchors 1020 may include an inflatable packer that inflates to secure the wellbore tractor 1002 into place.
A total stretch of the spooled cable may be less than that of a wireline cable advanced from the surface to the tool string. Accordingly, relative depth differentials may be more accurately determined since the tension and/or temperature on the spooled cable (or slickline) may be more evenly distributed over the shorter length of the spooled cable or slickline compared to the wireline of the tool string. The cable may further provide power, telemetry, and control to the tractor from the slickline spool 1006.
The wellbore tractor 1002 may move downhole through gravity and/or powered propulsion.
The wellbore tractor 1002 may further be anchored and used to unstick tools in vertical and/or horizontal positions. The wellbore tractor 1002 may further be configured to improve relative depth measurements locally in a horizontal and vertical system.
Numerous examples are provided herein to enhance understanding of the present disclosure. A specific set of statements are provided as follows.
Statement 1: A geothermal wellbore tractor comprising: a hydraulic subsystem; a plurality of wheels in communication with the hydraulic subsystem; and a slick line attachment mechanism in communication with the hydraulic subsystem and engaged to a slick line, wherein motion of the slick line is operable to generate power for the hydraulic subsystem, and wherein the hydraulic subsystem is operable to control motion of the plurality of wheels.
Statement 2: The geothermal wellbore tractor of Statement 2, wherein the slick line attachment mechanism comprises a pulley assembly comprising: a pulley wheel; and the slick line slidably engaged to the pulley wheel, wherein the pulley wheel is in communication with the hydraulic subsystem, wherein the pulley wheel is operable to be rotated by the slick line to generate power for the hydraulic subsystem, and wherein the slick line is a looped slick line.
Statement 3: The geothermal wellbore tractor of Statement 1 or Statement 2, further comprising an anchor.
Statement 4: The geothermal wellbore tractor of any one of Statements 1-3, wherein the hydraulic subsystem comprises an engaged mode and a disengaged mode.
Statement 5: The geothermal wellbore tractor of Statement 4, wherein in the engaged mode, the hydraulic subsystem is operable to cause the plurality of wheels to rotate, thereby moving the geothermal wellbore tractor through a geothermal wellbore.
Statement 6: The geothermal wellbore tractor of Statement 4 or 5, wherein in the disengaged mode, the slick line travels around the pulley wheel to convey one or more tools along the slick line.
Statement 7: The geothermal wellbore tractor of any one of Statements 5-7, wherein motion of the plurality of wheels is controlled by motion of the slick line.
Statement 8: The geothermal wellbore tractor of any one of Statements 1-7, wherein the slick line is operable to provide feedback on motion of the geothermal wellbore tractor.
Statement 9: The geothermal wellbore tractor of any one of Statements 1-8, wherein the hydraulic subsystem is operable to power one or more tools.
Statement 10: The geothermal wellbore tractor of Statement 1, further comprising a chemical steam subsystem in communication with the hydraulic subsystem and operable to generate power for the hydraulic subsystem, the chemical steam subsystem comprising: a first chamber operable to contain a first compound; a second chamber surrounding the first chamber, the second chamber operable to contain a second compound; and a steam engine.
Statement 11: The geothermal wellbore tractor of Statement 10, wherein the first compound comprises water, ammonia, and/or formic acid.
Statement 12: The geothermal wellbore tractor of Statement 11, wherein the second compound comprises barium oxide, calcium sulfate, calcium oxide, magnesium oxide, phosphorus pentoxide, silicon tetrachloride, sulfur trioxide, aluminum chloride, and/or zinc chloride.
Statement 13: The geothermal wellbore tractor of any one of Statements 10-12, wherein the first compound exothermically reacts with the second compound to produce steam, wherein the steam engine converts the steam to hydraulic power.
Statement 14: A geothermal wellbore system comprising: a slick line; a geothermal wellbore tractor comprising: a hydraulic subsystem; a plurality of wheels in communication with the hydraulic subsystem; an anchor; and a slick line attachment mechanism in communication with the hydraulic subsystem and engaged to the slick line; and a slick line truck operable to control motion of the slick line, wherein the motion of the slick line is operable to generate power for the hydraulic subsystem, and wherein the hydraulic subsystem is operable to control motion of the plurality of wheels.
Statement 15: The geothermal wellbore system of Statement 14, wherein the slick line attachment mechanism comprises a pulley assembly comprising: a pulley wheel; and the slick line slidably engaged to the pulley wheel, wherein the pulley wheel is in communication with the hydraulic subsystem, wherein the pulley wheel is operable to be rotated by the slick line to generate power for the hydraulic subsystem, and wherein the slick line is a looped slick line.
Statement 16: The geothermal wellbore system of Statement 15, wherein the hydraulic subsystem comprises an engaged mode and a disengaged mode.
Statement 17: The geothermal wellbore system of Statement 16, wherein in the engaged more, the hydraulic subsystem is operable to cause the plurality of wheels to rotate, thereby moving the geothermal wellbore tractor through a geothermal wellbore.
Statement 18: The geothermal wellbore system of any one of Statements 14-17, further comprising one or more wireline tools engaged with the slick line, wherein the hydraulic subsystem is operable to power the one or more wireline tools.
Statement 19: A geothermal wellbore tool power source comprising: A hydraulic subsystem; and a chemical steam subsystem in communication with the hydraulic subsystem and operable to provide power to the hydraulic subsystem, the chemical steam subsystem comprising: a first chamber operable to contain a first compound; a second chamber surrounding the first chamber and operable to contain a second compound; and a steam engine, wherein the first compound exothermically reacts with the second compound to produce high pressure steam, and wherein the steam engine converts the high pressure steam to hydraulic power for the hydraulic subsystem.
Statement 20: The geothermal wellbore tool power source of Statement 19, wherein the hydraulic subsystem powers one or more wireline tools.
Statement 21: A pulley-based deployment system comprising a pulley collar, an anchor coupled to the pulley collar and configured to anchor the pulley collar into a wellbore, and a cable looped about the pulley collar and configured to enable a logging tool to be conveyed from the wellbore to a surface of the wellbore.
Statement 22: The system of Statement 21, wherein the pulley collar is configured to be deployed from a bottom hole assembly of a drill string.
Statement 23: The system of Statement 21, wherein the anchor is configured to be deployed from a bottom hole assembly of a drill string.
Statement 24: The system of Statement 23, wherein the pulley collar is coupled to the anchor, whereby, when the anchor deploys from the bottom hole assembly, the anchor secures the pulley collar to the wellbore formation independently of the bottom hole assembly.
Statement 25: The system of Statement 21, further comprising a drill bit defining a drill bit channel therein, the drill bit configured to drill the wellbore, wherein the anchor and the pulley collar are deployed from the drill bit through the drill bit channel.
Statement 26: The system of Statement 21, wherein the anchor includes a drill for drilling into a wall of the wellbore to secure the pulley collar in the wellbore.
Statement 27: The system of Statement 21, wherein the pulley collar is configured to deploy into the wellbore from the anchor after the anchor is secured into a wall of the wellbore and after a drill string clears a position of the pulley collar.
Statement 28: The system of Statement 21, wherein the anchor includes at least one of a hydraulic mechanism or a mechanical mechanism each configured to actuate the anchor to secure the anchor to a wall of the wellbore.
Statement 29: The system of Statement 21, wherein the anchor is configured to drill a side pocket into the wellbore, and wherein the pulley collar is configured to deploy from the side pocket into the wellbore.
Statement 30: The system of Statement 21, wherein the cable includes at least one of a slickline, a wireline, a composite cable, an e-line, and a fiber optic cable.
Statement 31: The system of Statement 21, further comprising a cable spool configured to carry the cable, the cable spool configured to unspool the cable after the cable is looped around the pulley collar.
Statement 32: The system of Statement 31, further comprising a line attachment mechanism configured to loop the cable about the pulley collar and unspool the cable from the cable spool as the line attachment mechanism is retrieved from the wellbore.
Statement 33: The system of Statement 21, further comprising a logging tool configured to be conveyed from a surface of the wellbore downhole of the wellbore via the cable looped around the pulley collar.
Statement 34: A method for conveying wellbore tools into a wellbore comprising deploying an anchor, a pulley collar, and a cable into the wellbore via at least one of a drill string a wellbore tractor, a torpedo, or a pump mechanism, releasing the anchor from the at least one of the drill string or the wellbore tractor, securing the anchor within the wellbore to anchor the pulley collar in the wellbore, looping the cable about the pulley collar, and pulling the cable to a surface of the wellbore to form a looped cable in the wellbore.
Statement 35: The method of Statement 34, further comprising attaching a logging tool to the looped cable, deploying the logging tool into the wellbore via the looped cable, and measuring one or more wellbore parameters via the logging tool.
Statement 36: A tractor and logging system for wellbore operations comprising a tractor configured to travel down a wellbore, the tractor defining a tractor body, a plurality of modular compartments housing one or more wellbore tools, each modular compartment disposed in the tractor body and configured to be selectively deployed from the tractor, and a plurality of couplers configured to releasably couple each modular compartment to the tractor body, wherein the modular compartments are operable to be retrieved to a surface of the wellbore independently of the tractor.
Statement 37: The tractor and logging system of Statement 36, wherein the tractor is configured to be coupled to a cable looped about a pulley collar anchored in the wellbore.
Statement 38: The tractor and logging system of Statement 36, wherein the tractor includes a tractor channel configured to convey at least one modular compartment therethrough.
Statement 39: The tractor and logging system of Statement 36, wherein the plurality of couplers includes at least one of a magnetic release, a spring-loaded mechanism, a mechanical latch, an actuatable clip, a pressure sensitive release mechanism, a claw, a hook and loop device, a wet-mate connector, and a suction mechanism.
Statement 40: The tractor and logging system of Statement 36, further comprising at least one computing device in communication with the tractor, plurality of modular compartments, and plurality of couplers for controlling operation of each of the tractor, plurality of modular compartments, and plurality of couplers.
Statement 41: A system for performing logging operations within a horizontal section of a wellbore comprising an anchor securely positioned at or near a bottom of the well section, the anchor comprising a pulley collar, a cable connected to and operatively engaging the pulley collar and extending from the pulley collar to a surface of the wellbore to form at least two accessible cable ends at the surface, and a logging tool selectively attachable to at least one cable end at the surface, wherein the cable and pulley collar convey the logging tool from the surface into the horizontal section of the wellbore to perform logging operations and subsequently retrieve the logging tool to the surface.
Statement 42: The system of Statement 41, wherein the anchor comprising the pulley collar is initially deployed from a bottom hole assembly of a drilling system during drilling operations, wherein the anchor detaches from the bottom hole assembly and is anchored in position at or near the bottom of the well section prior to logging operations.
Statement 43: The system of Statement 41, wherein the anchor comprising the pulley collar is deployed from a side pocket of a bottom hole assembly configured to position the anchor securely into an offset position within the formation adjacent the wellbore prior to logging operations.
Statement 44: The system of Statement 41, wherein the anchor is deployed through a drill bit attached to a bottom hole assembly, the drill bit having a passage configured to allow the anchor comprising the pulley collar to pass therethrough into position within the formation at or near the bottom of the wellbore prior to logging operations.
Statement 41: A system for logging a horizontal section of a wellbore comprising an anchor positioned at or near a bottom of the wellbore, the anchor supporting a pulley collar, a cable loop extending from the pulley collar to the surface to provide two cable ends for tool attachment, and a logging tool attachable at the surface to be conveyed downhole and retrieved via the cable loop.
Statement 42: The system of Statement 41, wherein the anchor and pulley collar are deployed from a drill string or BHA during drilling and remain anchored in the wellbore after detachment from the drill string.
Statement 43: The system of Statement 41, wherein the anchor and pulley collar are deployed from a side pocket of a BHA into an offset position in the formation before logging operations.
Statement 44: The system of Statement 41, wherein the anchor and pulley collar are deployed through a drill bit having a passage configured to pass the anchor into the formation near the bottom of the wellbore.
Statement 45: The system of Statement 41, wherein the anchor drills directly into the formation to secure the pulley collar near the bottom of the wellbore.
Statement 46: The system of Statement 45, wherein after the drill string clears the anchor location, the pulley collar deploys outward from the anchor into the open wellbore.
Statement 47: The system of Statement 41, wherein the anchor includes a hydraulic or mechanical actuator that engages the formation to secure the pulley collar.
Statement 48: The system of Statement 45, wherein the anchor and pulley collar are ejected from a drilled side pocket into the main wellbore after the drill string clears the pocket.
Statement 49: The system of Statement 41, wherein the cable and pulley collar are pumped down through the drill string to an anchor already positioned downhole and mechanically connect to that anchor to complete the deployment system.
Statement 50: The system of Statement 41, wherein the cable comprises a slickline or a wireline.
Statement 51: The system of Statement 41, wherein the cable is unspooled from a spool housed in the BHA as the BHA is withdrawn to the surface, thereby establishing the cable loop between the anchored pulley collar and the surface.
Statement 52: The system of Statement 41, wherein the cable is stored on a spool located at the pulley collar and is unspooled from the pulley collar as the drill string is withdrawn.
Statement 53: The system of Statement 41, wherein the pulley collar includes one or more sensors comprising acoustic, optical, electromagnetic, pressure, or temperature sensors.
Statement 54: The system of Statement 41, wherein the cable loop is used to measure depth via tension, rotation, or cable markings along the path between the surface and the anchored pulley collar.
The system of Statement 41, wherein the anchor is conveyed downhole by a powered torpedo, the torpedo being electrically driven, chemically driven, jet-driven, or propeller-driven.
Statement 56: The system of Statement 41, wherein the logging tool is bi-directionally attached to the cable loop to allow upward or downward movement by adjusting tension on either side of the loop.
Statement 57: The system of Statement 41, wherein after reaching a selected depth, the downward conveyance connection to the logging tool is released so that logging proceeds using only the upward-directed portion of the cable.
Statement 58: The system of Statement 41, wherein the logging tool is a flask-type tool including thermal insulation to withstand high temperatures.
Statement 59: A method for logging a horizontal wellbore comprising anchoring an anchor and pulley collar at or near a bottom of the horizontal section, deploying a cable loop from the pulley collar to the surface, attaching a logging tool to a surface cable end, conveying the logging tool into the horizontal section using the cable loop, and performing logging operations.
Statement 60: A system for logging a horizontal wellbore comprising a BHA with a drill bit that is detachable and carries an anchor and pulley collar, a cable loop extending from the pulley collar to the surface, and a logging tool attachable to the cable loop, wherein after the drill bit and anchor detach from the BHA and remain downhole, the cable loop conveys and retrieves the logging tool, and wherein the anchor and drill bit may be retrieved to surface after logging.
Statement 61: A permanently installed downhole logging system comprising an anchor positioned within a cased section of a wellbore, the anchor supporting a pulley collar, a deployable line stored at or near the anchor and configured to be ejected into a production flow so the flow carries the line to the surface, a retrieval mechanism powered at least partly through the deployable line to rewind the line and form a cable loop between the surface and the pulley collar, wherein the cable loop and pulley collar convey logging tools into and out of the cased section.
Statement 62: A permanently deployed downhole monitoring system comprising an anchor secured within a wellbore, the anchor including one or more integrated sensors selected from pressure, temperature, acoustic, optical, and electromagnetic sensors, and a communication system configured to relay sensor measurements to the surface or to a remote location.
Statement 63: A system for deploying logging equipment comprising a drill string configured to drill a side pocket in a formation adjacent the wellbore, an anchor with a pulley collar deployable into the drilled side pocket, and a cable loop engaged with the pulley collar, wherein after positioning in the side pocket the anchor and pulley collar are ejected or extended into the main wellbore.
Statement 64: A system for deploying logging equipment comprising a drill string having a drill bit with a passage therethrough, an anchor with a pulley collar deployable through the drill bit passage to a downhole location, and a cable loop engaged with the pulley collar and extending to the surface.
Statement 65: A method of logging a horizontal wellbore comprising positioning an anchor with a pulley collar at a downhole location, deploying a cable loop from the surface to the pulley collar, conveying a flask-type logging tool along the cable loop to the pulley collar, and conducting logging operations within the horizontal wellbore using the flask-type logging tool.
Statement 66: A downhole tool assembly comprising multiple pressure-sealed modular compartments, each housing operational modules and each independently detachable and retrievable from the downhole assembly without retrieving the entire tool.
Statement 67: The assembly of Statement 66, wherein the modular compartments include at least one of sensors, fluid sampling modules, computation modules, telemetry modules, or power modules.
Statement 68: The assembly of Statement 66, wherein the modular compartments detach using mechanical, magnetic, hydraulic, pressure-sensitive, spring-loaded, rotating latch, sliding latch, or dissolvable release mechanisms.
Statement 69: The assembly of Statement 66, wherein replacement compartments are guided and secured using alignment guides, mechanical latches, magnetic or electromagnetic coupling, adhesives, pressure-sealed interfaces, or wet-mate connectors.
Statement 70: The assembly of Statement 66, wherein automated workflows using artificial intelligence, machine learning, or generative AI autonomously control detachment, retrieval, replacement, and reintegration of compartments.
Statement 71: A conveyance system comprising a tractor configured to retrieve and deploy modular compartments, the tractor being capable of direct conveyance, transfer to a pulley-based line, or dual-directional deployment within the wellbore.
Statement 72: The system of Statement 71, wherein the tractor includes a pass-through or side channel configured to permit compartment movement or fluid flow without disrupting operations.
Statement 73: The system of Statement 71, wherein the tractor includes compartments positioned opposite one another configured to transfer components internally through pressure-sealed interfaces.
Statement 74: The system of Statement 71, wherein compartment retrieval uses at least one of permanent magnets, electromagnetic coupling, mechanical claws, hook-and-loop devices, vacuum suction, or chemical adhesives.
Statement 75: The system of Statement 71, wherein optical or electrical sensors guide positioning of modular compartments during retrieval and deployment.
Statement 76: A multi-segmented pipeline pig comprising multiple sensor-equipped pig segments interconnected by flexible tethers, wherein each pig segment navigates bends independently and spacing along the tethers is dynamically adjustable based on real-time sensor data.
Statement 77: The system of Statement 76, wherein pig segments include at least one of acoustic, resistivity, magnetic, spectroscopic, optical, X-ray, gamma-ray, pressure, or nuclear magnetic resonance sensors.
Statement 78: The system of Statement 76, wherein initial pig segments perform preliminary sensing and subsequent segments dynamically adjust sensor frequencies, pulse rates, amplitudes, phases, or axial positions based on real-time analysis of the preliminary data.
Statement 79: The system of Statement 76, wherein pig segments communicate wirelessly or through transient physical contact with pipeline-mounted receivers to provide real-time or near-real-time data.
Statement 80: The system of Statement 76, wherein pig segments generate, sense, or adjust pipeline pressure pulses and interface with non-invasive pressure-monitoring systems.
Statement 81: An ESP monitoring and adjustment system comprising tethered sensors deployed upstream or downstream of an ESP, the sensing units configured to detect fluid properties and provide operational adjustment data in real time.
Statement 82: The system of Statement 81, wherein the sensors measure at least one of pressure, electrophoretic properties, magnetic properties, temperature, viscosity, density, spectroscopy data, nuclear magnetic resonance, resistivity, or thermal conductivity.
Statement 83: The system of Statement 81, wherein fluid mixing prior to sensing is performed by rotating fins, propellers, static fins, or dynamically adjustable fins.
Statement 84: The system of Statement 81, wherein the sensors are conveyed or positioned using magnetic or suction-based treads, wheels, rollers, spatially adaptive gripping mechanisms, or propellers to stabilize the sensing units against fluid flow.
Statement 85: The system of Statement 81, wherein automated workflows dynamically adjust ESP valve sizes, pump rates, torque settings, fluid routing, or storage pathways based on real-time fluid property measurements.
The embodiments shown and described above are only aspects. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the appended claims.
Claims
1. A pulley-based wellbore deployment system, comprising:
- a pulley collar;
- an anchor coupled to the pulley collar and configured to anchor the pulley collar into a wellbore; and
- a cable looped about the pulley collar and configured to enable a logging tool to be conveyed from the wellbore to a surface of the wellbore.
2. The system of claim 1, wherein the pulley collar is configured to be deployed from a bottom hole assembly of a drill string.
3. The system of claim 1, wherein the anchor is configured to be deployed from a bottom hole assembly of a drill string.
4. The system of claim 3, wherein the pulley collar is coupled to the anchor, whereby, when the anchor deploys from the bottom hole assembly, the anchor secures the pulley collar to a wellbore formation independently of the bottom hole assembly.
5. The system of claim 1, further comprising a drill bit defining a drill bit channel therein, the drill bit configured to drill the wellbore, wherein the anchor and the pulley collar are deployed from the drill bit through the drill bit channel.
6. The system of claim 1, wherein the anchor includes a drill for drilling into a wall of the wellbore to secure the pulley collar in the wellbore.
7. The system of claim 1, wherein the pulley collar is configured to deploy into the wellbore from the anchor after the anchor is secured into a wall of the wellbore and after a drill string clears a position of the pulley collar.
8. The system of claim 1, wherein the anchor includes at least one of a hydraulic mechanism or a mechanical mechanism each configured to actuate the anchor to secure the anchor to a wall of the wellbore.
9. The system of claim 1, wherein the anchor is configured to drill a side pocket into the wellbore, and wherein the pulley collar is configured to deploy from the side pocket into the wellbore.
10. The system of claim 1, wherein the cable includes at least one of a slickline a wireline, a composite cable, an e-line, and a fiber optic cable.
11. The system of claim 1, further comprising a cable spool configured to carry the cable, the cable spool configured to unspool the cable after the cable is looped around the pulley collar.
12. The system of claim 11, further comprising a line attachment mechanism configured to loop the cable about the pulley collar and unspool the cable from the cable spool as the line attachment mechanism is retrieved from the wellbore.
13. The system of claim 1, further comprising a logging tool configured to be conveyed through the wellbore from a surface of the wellbore via the cable looped around the pulley collar.
14. A method for conveying wellbore tools into a wellbore, comprising:
- deploying an anchor, a pulley collar, and a cable into the wellbore via at least one of a drill string, a wellbore tractor, a torpedo, or a pump mechanism;
- releasing the anchor from the at least one of the drill string or the wellbore tractor;
- securing the anchor within the wellbore to anchor the pulley collar in the wellbore;
- looping the cable about the pulley collar; and
- pulling the cable to a surface of the wellbore to form a looped cable in the wellbore.
15. The method of claim 14, further comprising: attaching a logging tool to the looped cable; deploying the logging tool into the wellbore via the looped cable; and measuring one or more wellbore parameters via the logging tool.
16. A tractor and logging system for wellbore operations, comprising:
- a tractor configured to travel down a wellbore, the tractor defining a tractor body;
- a plurality of modular compartments housing one or more wellbore tools, each modular compartment disposed in the tractor body and configured to be selectively deployed from the tractor; and
- a plurality of couplers configured to releasably couple each modular compartment to the tractor body,
- wherein the plurality of modular compartments are configured to be retrieved to a surface of the wellbore independently of the tractor.
17. The tractor and logging system of claim 16, wherein the tractor is configured to be coupled to a cable looped about a pulley collar anchored in the wellbore.
18. The tractor and logging system of claim 16, wherein the tractor includes a tractor channel configured to convey at least one modular compartment therethrough.
19. The tractor and logging system of claim 16, wherein the plurality of couplers includes at least one of a magnetic release, a spring-loaded mechanism, a mechanical latch, an actuatable clip, a pressure sensitive release mechanism, a claw, a hook and loop device, a wet-mate connector, and a suction mechanism.
20. The tractor and logging system of claim 16 further comprising at least one computing device in communication with the tractor, the plurality of modular compartments, and the plurality of couplers for controlling operation of each of the tractor, the plurality of modular compartments, and the plurality of couplers.
Type: Application
Filed: Feb 11, 2026
Publication Date: Aug 20, 2026
Applicant: HALLIBURTON ENERGY SERVICES, INC. (Houston, TX)
Inventors: Christopher Jones (Houston, TX), Wei Zhang (Houston, TX), George Tevis (Houston, TX), Darren Gascooke (Houston, TX), Glenn Wilson (Houston, TX), Anthony VanZuilekom (Houston, TX), Daniel Stark (Houston, TX)
Application Number: 19/536,486
