Wired casing

Abstract

The present invention involves a method and apparatus for monitoring conditions downhole and/or manipulating downhole tools by placing electrical wire on a casing string while drilling with casing. Wire is inserted into a groove within the casing string while drilling with the casing string into a formation. The wire connects downhole equipment to surface equipment. Multiple casing strings may be drilled into the formation while wire is simultaneously inserted into a groove therein.

1 . A method of wiring casing while drilling with casing, comprising: 
 lowering a first casing string with an earth removal member operatively connected to its lower end into an earth formation; and    placing wire on the first casing string while lowering the first casing string.    
     
     
         2 . The method of  claim 1 , wherein the wire is at least partially sub-flushed to a surface of the first casing string.  
     
     
         3 . The method of  claim 1 , wherein the wire electrically connects surface equipment to downhole equipment.  
     
     
         4 . The method of  claim 1 , further comprising: 
 connecting a second casing string to the first casing string;    lowering the first casing string into the earth formation; and    placing the wire on the second casing string while lowering the first casing string.    
     
     
         5 . The method of  claim 4 , wherein the wire is sub-flushed to a surface of the first casing string and the second casing string.  
     
     
         6 . The method of  claim 4 , wherein connecting the second casing string to the first casing string comprises substantially aligning a groove in the second casing string with a groove in the first casing string.  
     
     
         7 . The method of  claim 6 , wherein substantially aligning the grooves comprises substantially aligning an enlarged portion of the groove in the first casing string with an enlarged portion of the groove in the second casing string.  
     
     
         8 . The method of  claim 6 , wherein substantially aligning the groove in the second casing string with the groove in the first casing string comprises substantially aligning timing marks.  
     
     
         9 . The method of  claim 8 , wherein the first casing string and second casing string are pre-machined to substantially align the timing marks at a predetermined torque.  
     
     
         10 . The method of  claim 1 , wherein placing wire on the first casing string comprises dispensing the wire from a spool located below a rig floor while lowering the first casing string.  
     
     
         11 . The method of  claim 1 , wherein the wire is placed on the first casing string above the rig floor.  
     
     
         12 . The method of  claim 1 , further comprising monitoring conditions within the earth formation through the wire while lowering the first casing string.  
     
     
         13 . The method of  claim 1 , further comprising manipulating one or more downhole tools through the wire while lowering the first casing string.  
     
     
         14 . The method of  claim 1 , further comprising using the wire to sense a geophysical parameter while lowering the first casing string.  
     
     
         15 . The method of  claim 1 , wherein a sensing device is located at a lower end of the wire.  
     
     
         16 . The method of  claim 1 , further comprising: 
 lowering the first casing string to a first depth within the earth formation; and    operating one or more downhole tools through signals sent through the wire.    
     
     
         17 . The method of  claim 16 , wherein the one or more downhole tools comprises a cementing apparatus.  
     
     
         18 . The method of  claim 16 , wherein the one or more downhole tools comprises one or more packers.  
     
     
         19 . The method of  claim 16 , wherein the one or more downhole tools comprises one or more valves.  
     
     
         20 . A method of wiring casing while drilling with casing, comprising: 
 lowering a first casing string with an earth removal member operatively connected to its lower end into an earth formation;    placing a first wire on the first casing string while lowering the first casing string to a first depth within the formation;    lowering a second casing string with an earth removal member operatively connected to its lower end into the formation; and    placing a second wire on the second casing string while lowering the second casing string to a second depth within the formation.    
     
     
         21 . The method of  claim 20 , further comprising inductively coupling the first wire to the second wire.  
     
     
         22 . The method of  claim 21 , wherein the wire is substantially sub-flushed to a surface of the first casing string.  
     
     
         23 . The method of  claim 21 , wherein the first wire and the second wire electrically connect surface equipment to downhole equipment.  
     
     
         24 . The method of  claim 23 , wherein surface equipment is connected to the first wire and downhole equipment is connected to the second wire.  
     
     
         25 . The method of  claim 20 , wherein the first wire is dispensed from a first spool and the second wire is dispensed from a second spool.  
     
     
         26 . An apparatus for use in transmitting signals from within a wellbore to a surface of the wellbore, comprising: 
 downhole equipment for sensing information from within the wellbore;    surface equipment for processing the information;    a wire for transmitting the information from the downhole equipment to the surface equipment; and    a first casing string with an earth removal member operatively connected to its lower end, wherein the first casing string houses the wire.    
     
     
         27 . The apparatus of  claim 26 , wherein the downhole equipment comprises a sensor.  
     
     
         28 . The apparatus of  claim 26 , wherein the surface equipment comprises a processing unit.  
     
     
         29 . The apparatus of  claim 26 , further comprising a first casing coupling connected to an upper end of the first casing string, wherein the first casing coupling houses a portion of the wire above the first casing string.  
     
     
         30 . The apparatus of  claim 26 , wherein the wire is housed in a continuous groove formed within the first casing string and the first casing coupling.  
     
     
         31 . The apparatus of  claim 30 , wherein the continuous groove comprises an enlarged groove portion of the first casing string substantially aligned with an enlarged groove portion of the first casing coupling.  
     
     
         32 . A method for monitoring conditions within a wellbore by wiring casing, comprising: 
 lowering a first casing section to a first depth within a formation; and    placing wire on the first casing section while lowering the first casing section, wherein the wire is at least partially sub-flushed to a surface of the first casing section.    
     
     
         33 . The method of  claim 32 , wherein the wire electrically connects surface equipment to downhole equipment.  
     
     
         34 . The method of  claim 32 , further comprising: 
 connecting the first casing section to a second casing section;    lowering a second casing section to a second depth within the formation; and    placing the wire on the second casing section while lowering the second casing section, wherein the wire is at least partially sub-flushed to a surface of the second casing section.    
     
     
         35 . The method of  claim 34 , wherein the wire is continuous across the connection of the first casing section to the second casing section.  
     
     
         36 . The method of  claim 34 , wherein the wire is continuously sub-flushed across the connection of the first casing section to the second casing section.  
     
     
         37 . An apparatus for use in transmitting signals from within a wellbore to a surface of the wellbore, comprising: 
 downhole equipment for sensing information from within the wellbore;    surface equipment for processing the information;    a wire for transmitting the information from the downhole equipment to the surface equipment; and    a first casing section comprising a groove therein for at least partially sub-flushing the wire to the surface of the first casing section.    
     
     
         38 . The apparatus of  claim 37 , further comprising a second casing section comprising a groove therein for at least partially sub-flushing the wire to the surface of the second casing section, wherein the second casing section is connected to the first casing section.  
     
     
         39 . The apparatus of  claim 38 , wherein the wire is continuously sub-flushed across the connection of the first casing section to the second casing section.  
     
     
         40 . The apparatus of  claim 38 , wherein the groove of the first casing section comprises an enlarged portion which connects to an enlarged portion of the groove of the second casing section.  
     
     
         41 . An apparatus for use in transmitting signals from within a wellbore to a surface of the wellbore, comprising: 
 downhole equipment for sensing information from within the wellbore;    surface equipment for processing the information;    a wire for transmitting the information from the downhole equipment to the surface equipment;    a first tubular comprising a groove therein for at least partially subflushing the wire to a surface of the first tubular; and    a second tubular comprising a groove therein for at least partially subflushing the wire to a surface of the second tubular,    wherein the first tubular is connected to the second tubular and the wire is sub-flushed across the connection.    
     
     
         42 . A method for monitoring conditions within a wellbore while lowering tubulars into the wellbore, comprising: 
 lowering a first tubular into the wellbore;    placing wire on the first tubular while lowering the first tubular, wherein the wire is at least partially sub-flushed to a surface of the first tubular;    connecting the first tubular to a second tubular;    lowering the second tubular into the wellbore; and    placing wire on the second tubular while lowering the second tubular, wherein the wire is at least partially sub-flushed to a surface of the second tubular,    wherein the wire is sub-flushed across the connection of the first tubular to the second tubular.