System and method for downhole blowout prevention

Abstract

A system for monitoring and controlling fluid flow through a borehole in an earth formation is disclosed. The system includes: a downhole tool configured to be movable within the borehole; and a plurality of interchangeable modules disposed within the downhole tool, the plurality of interchangeable modules including at least a sensor module for detecting a property change in the borehole and a packer module for sealing a portion of the borehole in response to the property change. Each of the plurality of interchangeable modules includes a connection configuration, the connection configuration of one of the modules being removably engageable with at least another of the modules. A method of monitoring and controlling fluid flow through a borehole in an earth formation is also disclosed.

1 . A system for monitoring and controlling fluid flow through a borehole in an earth formation, the system comprising:
 a downhole tool configured to be movable within the borehole; and   a plurality of interchangeable modules disposed within the downhole tool, the plurality of interchangeable modules including at least a sensor module for detecting a property change in the borehole and a packer module for sealing a portion of the borehole in response to the property change,   each of the plurality of interchangeable modules including a connection configuration, the connection configuration of one of the modules being removably engageable with at least another of the modules.   
   
   
       2 . The system of  claim 1 , wherein the downhole tool includes a segmented tool body having a plurality of segments, each segment having compatible connection mechanisms to allow each of the plurality of interchangeable modules to be replaced. 
   
   
       3 . The system of  claim 1 , wherein the connection includes a common connection configuration, the connection configuration of one of the modules being engageable with any other of the modules. 
   
   
       4 . The system of  claim 1 , wherein the property change is detection of an influx of fluid or loss of fluid circulation. 
   
   
       5 . The system of  claim 1 , wherein the sensor module includes at least one additional sensor for measuring selected characteristics of at least one of the borehole and the formation 
   
   
       6 . The system of  claim 5 , wherein the property change is selected from a change in at least one of a pressure, flow rate, gas content and fluid composition. 
   
   
       7 . The system of  claim 1 , further comprising at least one additional module selected from at least one of an upper crossover module, a power/pulser module, a communication module, a bypass module, a decoder module and a lower crossover module. 
   
   
       8 . The system of  claim 1 , wherein the connection configurations are selected from one of a shaft connection, a threaded connection, a bayonet connection and a pin connection. 
   
   
       9 . The system of  claim 1 , wherein the packer module includes an actuator and a packer, the actuator configured to cause the packer to extend radially toward a surface of the borehole. 
   
   
       10 . The system of  claim 9 , wherein the actuator includes at least one valve, and the packer is an inflatable member surrounding an annulus, the valve being actuateable to open a circulation port and cause drilling fluid to enter the annulus and inflate the packer. 
   
   
       11 . A method of monitoring and controlling fluid flow through a borehole in an earth formation, the method comprising:
 disposing a plurality of interchangeable modules within a downhole tool, the plurality of interchangeable modules including at least a sensor module and a packer module, each of the plurality of interchangeable modules including a connection configuration, the connection configuration of one of the modules being removably engageable with at least another of the modules.   detecting a change in property in the borehole by the sensor module; and   responsive to the change in property being greater than a selected threshold, actuating the packer sub to seal a portion of the borehole.   
   
   
       12 . The method of  claim 11 , wherein detecting the change in property includes detecting an influx of fluid or loss of fluid circulation. 
   
   
       13 . The method of  claim 11 , further comprising measuring at least one additional selected characteristic of at least one of the borehole and the formation. 
   
   
       14 . The method of  claim 11 , wherein detecting the change in property includes detecting a change in at least one of a pressure, flow rate, gas content and fluid composition. 
   
   
       15 . The method of  claim 11 , wherein disposing the plurality of interchangeable modules includes connecting each of the plurality of modules together via the common connection configuration. 
   
   
       16 . The method of  claim 11 , wherein the packer module includes an actuator and a packer, and actuating the packer module includes causing the packer to extend radially toward a surface of the borehole. 
   
   
       17 . The method of  claim 16 , wherein the actuator includes at least one valve, the packer is an inflatable member surrounding an annulus, and actuating the packer module includes opening a circulation port and causing drilling fluid to enter the annulus and inflate the packer. 
   
   
       18 . The method of  claim 11 , further comprising circulating a fluid having a selected density in a section of the borehole to equalize pressure in the borehole. 
   
   
       19 . The method of  claim 11 , wherein the plurality of interchangeable modules includes at least one additional module selected from at least one of an adapter sub, a power/pulser sub, a bypass sub, and a decoder sub. 
   
   
       20 . The method of  claim 11 , wherein the connection configurations are selected from one of a shaft connection, a threaded connection, a bayonet and a pin connection.