Dual transducer communications node for downhole acoustic wireless networks and method employing same

• US 10,415,376 B2
• Filed: 08/01/2017
• Issued: 09/17/2019
• Est. Priority Date: 08/30/2016
• Status: Active Grant

• Current Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Original Assignee: Exxonmobil Upstream Research Company (Exxon Mobil Corporation)
• Inventors: Song, Limin, Zhang, Yibing, Walker, Katie M., Wolf, Henry Alan
• Primary Examiner(s): Sherwin, Ryan W
• Application Number:
  US15/666,292
• Publication Number:
  US 20180058207A1
• Time in Patent Office: 777 Days
• CPC Class Codes: E21B 47/005 Monitoring or checking of cementation quality or level
• CPC Class Codes: E21B 47/017 Protecting measuring instruments
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves

Abstract

An electro-acoustic communications node system and method for downhole wireless telemetry, the system including a housing for mounting to or with a tubular body; a receiver transducer positioned within the housing, the receiver transducer structured and arranged to receive acoustic waves that propagate through the tubular member; a transmitter transducer and a processor, positioned within the housing and arranged to retransmit the acoustic waves to another acoustic receiver in a different housing, using the tubular member for the acoustic telemetry. In some embodiments, the transducers may be piezoelectric transducers and/or magnetostrictive transducers. Included in the housing is also a power source comprising one or more batteries. A downhole wireless telemetry system and a method of monitoring a hydrocarbon well are also provided.

Claims

1. An electro-acoustic communications node assembly for a downhole wireless telemetry system, comprising:

a housing having a mounting face for mounting to a surface of a tubular body;

a receiver transducer positioned within the housing, the receiver transducer structured and arranged to receive acoustic waves that propagate through the tubular member, using multiple frequency shift keying (MFSK), in a frequency range between 50 kHz and 120 kHz;

a transmitter transducer positioned within the housing, the transmitter transducer structured and arranged to retransmit the received acoustic waves, using MFSK, in the frequency range, through the tubular member to another receiver transducer;

electronic circuits positioned within the housing for electrically communicating with each of the receiver transducer and the transmitter transducer;

a processor in communication with each of the receiver transducer and transmitter transducer via the electronic circuits; and

a power source comprising one or more batteries positioned within the housing for powering the transmitter transducer and the receiver transducer.

2. The assembly of claim 1, wherein at least one of the receiver transducer and the transmitter transducer is one of a piezoelectric device and a magnetorestrictive device.

3. The assembly of claim 2, wherein the piezoelectric transmitter comprises multiple piezoelectric disks, each piezoelectric disk having at least a pair of electrodes connected in parallel with an adjacent piezoelectric disk.

4. The assembly of claim 3, wherein a single voltage is applied equally to each piezoelectric disk.

5. The assembly of claim 3, wherein the mechanical output of the piezoelectric transmitter is increased by increasing the number of disks while applying the same voltage.

6. The assembly of claim 2, wherein the piezoelectric receiver comprises one of

multiple piezoelectric disks, each piezoelectric disk having at least a pair of electrodes connected in series with an adjacent piezoelectric disk, or

a single piezoelectric disk, the single piezoelectric disk having a thickness equivalent to the total thickness of the multiple piezoelectric disks to achieve the same sensitivity.

7. The assembly of claim 2, wherein at least one of the receiver transducer and the transmitter transducer include an end mass.

8. The assembly of claim 7, wherein the electronics circuits include separate impedance matching for a receiving transducer circuit and a transmitter transducer circuit, and wherein the end mass and electrical impedance matching are collectively selected to optimize telemetry parameter for transmit, receive, and/or energy consumption.

9. The assembly of claim 1, wherein the electronic circuits repeat the received acoustic waves to retransmit the received acoustic waves by the transmitter.

10. The assembly of claim 1, wherein the electronic circuits decode the received acoustic waves and then recode the received acoustic waves to be retransmitted by the transmitter transducer.

11. The assembly of claim 1, wherein the electronics circuit is comprised of two separate electronics circuits to optimize the performance of the receiver transducer and the transmitter transducer.

12. The assembly of claim 1, wherein the electronics circuits include separate impedance matching for a receiving transducer circuit and a transmitter transducer circuit.

13. The assembly of claim 1, wherein the housing includes a first end and a second end, each of which have a clamp associated therewith for clamping to an outer surface of the tubular body.

14. The assembly of claim 1, wherein the receiver transducer receiving the sent acoustic signal is positioned in the same physical housing as the transmitting transducer.

15. The assembly of claim 1, wherein the housing further comprises distinct housings for each of the receiver transducer and the transmitter transducer, and the distinct housings are in electrical communication with the processor via the electronic circuits, and the processor is positioned within at least one of the distinct housings.

16. The assembly of claim 1, wherein the frequency range is between 79 kHz and 90 kHz.

17. A downhole wireless telemetry system, comprising:

at least one sensor disposed along a tubular body;

at least one sensor communications node placed along the tubular body and affixed to a wall of the tubular body, the sensor communications node being in at least one of acoustic and electrical communication with the at least one sensor and configured to receive signals therefrom;

a topside communications node placed proximate a surface;

a plurality of electro-acoustic communications nodes spaced along the tubular body and attached to a wall of the tubular body, each electro-acoustic communications node comprising a housing having a mounting face for mounting to a surface of the tubular body;

a receiver transducer positioned within the housing, the receiver transducer structured and arranged to receive acoustic waves that propagate through the tubular member, using multiple frequency shift keying (MFSK), in a frequency range between 50 kHz and 120 kHz;

a transmitter transducer positioned within the housing, the transmitter transducer structured and arranged to transmit acoustic waves through the tubular member, using MFSK, in the frequency range between 50 kHz and 120 kHz; and

a power source comprising one or more batteries positioned within the housing powering electronics circuits interfaced to the transmitter and receiver transducers;

wherein the electro-acoustic communications nodes are configured to transmit signals received from the at least one sensor communications node to the topside communications node in a substantially node-to-node arrangement.

18. The downhole wireless telemetry system of claim 17, wherein at least one of the receiver transducer and the transmitter transducer is one of a piezoelectric device and a magnetorestrictive device.

19. The downhole wireless telemetry system of claim 18, wherein at least one of a piezoelectric receiver transducer and a piezoelectric transmitter transducer include an end mass.

20. The downhole wireless telemetry system of claim 17, wherein the at least one sensor communications node is configured to transmit signals to the at least one sensor.

21. The downhole wireless telemetry system of claim 17, wherein the electronics circuit comprises separate circuits for each of the transmitter transducer and receiver transducer to separately optimize circuit performance of each of a receiver circuit and a transmitter circuit.

22. The system of claim 17, wherein the frequency range is between 79 kHz and 90 kHz.

23. A method of monitoring a hydrocarbon well having a tubular body comprising:

providing one or more sensors positioned along the tubular body;

receiving signals from the one or more sensors;

transmitting those signals via a sensor transmitter to an electro-acoustic communications node attached to a wall of the tubular body, the electro-acoustic communications node comprising a housing;

a receiver transducer positioned within the housing, the receiver transducer structured and arranged to receive acoustic waves that propagate through the tubular member;

a transmitter transducer positioned within the housing, the transmitter transducer structured and arranged to transmit acoustic waves through the tubular member;

electronics circuits interfaced to the transmitter and receiver transducers; and

a power source comprising one or more batteries positioned within the housing;

transmitting signals received by the electro-acoustic communications node to at least one additional electro-acoustic communications node, using multiple frequency shift keying (MFSK), in a frequency range between 50 kHz and 120 kHz; and

transmitting, using MFSK, signals received by the at least one additional intermediate communications node, in the frequency range between 50 kHz and 120 kHz to a topside communications node.

24. The method of claim 23, wherein at least one of the transmit transducer and the receive transducer is one of a piezoelectric device and a magnetorestrictive device.

25. The method of claim 23, further comprising:

providing the electronics circuits with separate impedance matching for each transducer; and

optimizing an impedance in a receiving transducer circuit with an impedance of a transmitter circuit.

26. The method of claim 23, further comprising:

sending an acoustic signal from the transmitter transducer of the electro-acoustic communications node and receiving the sent acoustic signal at the receiver transducer; and

determining from the received acoustic response at the receiver transducer a well parameter of the hydrocarbon well.

27. The method of claim 26, further comprising repeating the method at a different time with respect to a previous time and measuring the change in acoustic response between the previous time and the different time to determine whether a change has occurred in a well parameter.

28. The method of claim 23, wherein the frequency range is between 79 kHz and 90 kHz.