Modular Data Acquisition for Drilling Operations

Abstract

Data associated with drilling operations, downhole components, wellbores, or well formations can be acquired by providing one or more data acquisition modules having one or more sensors into one or more recessed chambers formed within a drill bit, stabilizer reamer, or other downhole tool, enabling direct rather than inferential data to be obtained for analysis. The modules can be programmed with pre-selected trigger thresholds, such that data acquisition is initiated when certain conditions are met, and can be interchanged with other types of modules at the surface.

What is claimed is: 
     
         1 . A data acquisition module comprising:
 a sensor housing or body designed to protect and house the sensor electronics and allow installation into a downhole member;   and at least one sensor within the sensor housing or body configured to acquire local data associated with the at least one sensor relative to the location of the at least one sensor body in the drill string and in communication with a data storage means.   
     
     
         2 . The data acquisition module of  claim 1 , wherein the sensor housing or body is secured within a recessed chamber designed into a downhole member such that the positioning of the recessed chamber does not interfere with tool operation or compromise functionality. 
     
     
         3 . The data acquisition module of  claim 1 , wherein the sensor housing or body may be secured to a downhole member using suitable bolts or other attachment means and in which the downhole member has been fitted with threaded bolt holes or other attachment means, the position of which does not interfere with tool operation or compromise functionality. 
     
     
         4 . The data acquisition module of  claim 1 , wherein the sensor housing or body may be ring-shaped, and contain one or more sensors or one or more recessed chambers or other means of attaching one or more sensors housings or bodies, and attached to the downhole member via compression and/or bolts or other attachment means and in which the position of the ring-shaped sensor housing or body does not interfere with tool operation or compromise functionality. 
     
     
         5 . The data acquisition module of  claim 1 , wherein the data storage means further comprises at least one preset value and computer instructions for a processor associated with the data acquisition module to actuate the at least one sensor to acquire data responsive to a condition that deviates from the at least one preset value. 
     
     
         6 . The data acquisition module of  claim 1 , wherein the data acquisition module comprises a timer and/or counter circuit, or combination thereof, for data normalization relative to operations of the drilling rig associated with the downhole sensor. 
     
     
         7 . The data acquisition module of  claim 1 , wherein the at least one sensor disposed within the data acquisition module may include any type of sensor suitable for downhole applications and which can physically fit within the space available within the data acquisition module, including, but not limited to, accelerometers, strain gauges, temperature sensors, radiation sensors, anti-collision sensors, sonic sensors, acoustic sensors, pressure sensors, flow sensor, hydrocarbon detection sensors, vibration sensors, among others. 
     
     
         8 . The data acquisition module of  claim 1 , wherein the data acquisition module may include power storage, power generation and/or battery storage means within the data acquisition module to provide a power source for the at least one least sensor disposed within the data acquisition module. 
     
     
         9 . The data acquisition module of  claim 8 , wherein the power generation means within the data acquisition module uses naturally occurring conditions, such as temperature and or vibrations, to generate the power provided by the power generation means. 
     
     
         10 . The data acquisition module of  claim 8 , wherein the power generation means uses high temperature present proximal to the data acquisition module further to provide cooling and/or temperature regulation to the at least one sensor and other electrical equipment disposed within the data acquisition module. 
     
     
         11 . The data acquisition module of  claim 1 , wherein the sensor housing or body is manufactured from a high-strength plastic to allow wireless downloading of data stored within the memory of the data acquisition module. 
     
     
         12 . A system for data acquisition during wellbore operations, the system comprising: at least one data acquisition module of  claim 1 , disposed within or upon a downhole member designed for coupling within a drill string and adapted to acquire data associated with the downhole member; geologic formation data proximate to the downhole member and module, environmental conditions proximal the downhole member and module, or combinations thereof. 
     
     
         13 . The system of  claim 12 , wherein a plurality of sensors are disposed in a plurality of locations within a drill string, or a plurality of downhole members designed for coupling as a drill string, and adapted to acquire data relative to physical conditions of the drillstring or its location within the wellbore. 
     
     
         14 . The system of  claim 13 , wherein the data collected by the multiple sensors disposed in a plurality of locations within the drill string are processed and analyzed to create a profile or digital “system signature” for the drill string. 
     
     
         15 . A method for acquiring data associated with a specific downhole member during drilling or similar operations, the method comprising the steps of:
 providing at least one downhole sensor within a downhole member;   performing an operation affecting at least one condition associated with the downhole member or its location in the wellbore; and   using the at least one sensor to acquire data associated with the downhole member or its location in the wellbore   
     
     
         16 . The method of  claim 15 , wherein the step of using the at least one downhole sensor to acquire data using a processor associated with the at least one sensor to compare the at least one condition with at least one preset value and actuating the at least one sensor to acquire data responsive to a condition that deviates from the at least one preset Value. 
     
     
         17 . The method of  claim 15 , wherein the data acquired by the at least one downhole sensor is used to develop a profile or digital “system signature” of behaviors of the downhole member within which it is contained, relative to the type of the downhole sensor data acquired.