Method for multi-phase data communications and control over an ESP power cable

• US 6,587,037 B1
• Filed: 05/05/2000
• Issued: 07/01/2003
• Est. Priority Date: 02/08/1999
• Status: Expired due to Fees

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Besser, Gordon L., Rider, Jerald, Toomey, Dan D., Knox, Dick L.
• Primary Examiner(s): Lieu, Julie
• Application Number:
  US09/566,841
• Time in Patent Office: 1,152 Days
• Field of Search: 340/310.01, 340/310.02, 340/310.03, 340/310.06, 340/310.7, 340/310.8
• US Class Current: 340/854.9
• CPC Class Codes: E21B 43/128 Adaptation of pump systems with down-hole electric drives
• CPC Class Codes: E21B 47/008 Monitoring of down-hole pump systems, e.g. for the detection of "pumped-off" conditions
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: F04D 13/10 adapted for use in mining bore holes
• CPC Class Codes: F04D 15/0027 Varying behaviour or the very pump F04D15/0055 and F04D29/46 take precedence
• CPC Class Codes: F04D 15/0066 by changing the speed, e.g. of the driving engine
• CPC Class Codes: F04D 15/0088 Testing machines
• CPC Class Codes: F04D 9/002 by means in the very pump F04D9/041 takes precedence
• CPC Class Codes: H04B 2203/5458 Monitor sensor; Alarm systems
• CPC Class Codes: H04B 2203/5466 using three phases conductors
• CPC Class Codes: H04B 2203/5475 adapted for drill or well combined with data transmission
• CPC Class Codes: H04B 2203/5491 using filtering and bypassing
• CPC Class Codes: H04B 3/54 Systems for transmission via power distribution lines

Abstract

A three phase power cable is employed to transmit data encoded in a phase-to-phase manner within a high frequency carrier signal transmitted simultaneously with power transmitted from surface equipment to downhole components. The high frequency carrier signal is transmitted on all conductors of the power cable, with the signal carried on at least two phases or conductors modulated between the two conductors to encode data between the two phases. Any modulation technique may be employed. Multiple phase-to-phase signals may be encoded and transmitted between different pairs of the power cable conductors, or the same data may be encoded and transmitted in multiple phase-to-phase signals in either a single-ended or differential manner. The high frequency carrier may be employed to transmit data from sensors downhole to the surface equipment, control signals from the surface equipment to the downhole components, or both.

Claims

1. A method of communication over a power cable, comprising:

transmitting power over a three phase power cable connecting surface equipment to downhole components;

transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power by;

transmitting a first phase-to-phase, high frequency signal representing data between a first conductor pair within the three phase power cable; and

transmitting a second phase-to-phase, high frequency signal representing an inverse of the data between a second conductor pair within the three phase power cable; and

decoupling the phase-to-phase signal from the power transmitted over the power cable.

2. The method of claim 1, wherein the step of transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power further comprises:

transmitting a signal independent of a ground reference by altering a relative voltage between the at least two conductors.

3. The method of claim 1, wherein the step of transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power further comprises:

supplying operational power to downhole sensing or control components;

transmitting control signals from the surface equipment to the downhole components; and

transmitting data from the downhole components to the surface equipment.

18. The method of claim 1, wherein the step of transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power further comprises:

modulating a load current between the two phases.

19. The method of claim 1, wherein the step of transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power further comprises:

employing a constant load current to produce the phase-to-phase signal.

20. The method of claim 1, wherein the step of transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power further comprises:

employing a frequency higher than a frequency of the three phase power for the phase-to-phase signal.

4. A method of communication over a power cable, comprising:

transmitting a signal over a multi-conductor power cable connecting surface equipment to downhole components, the signal including three phase power for the downhole components and a high frequency signal modulated between at least two conductors of the power cable and independent of a ground reference, wherein the high frequency signal includes a first phase-to-phase, high frequency signal representing data between a first conductor pair within the power cable and a second phase-to-phase, high frequency signal representing an inverse of the data between a second conductor pair within the power cable; and

sensing the high frequency signal from the signal received over the power cable at the downhole components.

5. The method of claim 4, wherein the step of transmitting a signal over a multi-conductor power cable connecting surface equipment to downhole components further comprises:

transmitting an electrical signal having a current or voltage modulated by a modulation technique selected from frequency modulation, amplitude modulation, frequency shift key modulation, and phase shift key modulation.

6. The method of claim 4, wherein the step of transmitting a signal over a multi-conductor power cable connecting surface equipment to downhole components further comprises:

transmitting control signals from the surface equipment to the downhole components; and

transmitting data from the downhole components to the surface equipment.

7. The method of claim 6, wherein the step of sensing the high frequency signal from the signal received over the power cable at the downhole components further comprises:

filtering the high frequency signal from the three phase power within the signal received over the power cable; and

filtering the three phase power from the high frequency signal within the signal received over the power cable.

8. The method of claim further comprising:

transmitting the three phase power to an electrical submersible pump motor;

rectifying the high frequency signal to provide operational power to selected downhole components; and

subtracting the filtered high frequency signal received on a first conductor connector to a first three phase power cable conductor from the filtered high frequency signal received on a second conductor connected to a second three phase power cable conductor to extract data from the filtered high frequency signal.

9. A system for communication over a power cable, comprising:

surface equipment connected to downhole components by a three phase power cable transmitting power to the downhole components;

a driver transmitting a phase-to-phase signal over at least two conductors of the power cable concurrently with the power, the driver including a modulator generating a first phase-to-phase, high frequency signal representing data between a first conductor pair within the three phase power cable a second phase-to-phase, high frequency signal representing an inverse of the data between a second conductor pair within the three phase power cable; and

a receiver decoupling the phase-to-phase signal from the power received over the power cable.

10. The system of claim 9, wherein the driver further comprises:

a driver transmitting a signal independent of a ground reference by altering a relative voltage between the at least two conductors.

11. The system of claim 9, wherein the driver further comprises:

a first driver supplying operational power to downhole sensing or control components and transmitting control signals from the surface equipment to the downhole components; and

a second driver transmitting data from the downhole components to the surface equipment.

12. A system for communication over a power cable, comprising:

surface equipment transmitting a signal over a multi-conductor power cable connecting surface equipment to downhole components, the signal including three phase power for the downhole components and a high frequency signal modulated between at least two conductors of the power cable and independent of a ground reference, the surface equipment including a driver transmitting a first phase-to-phase, high frequency signal representing data between a first conductor pair within the power cable and a second phase-to-phase, high frequency signal representing an inverse of the data between a second conductor pair within the power cable; and

a receiver within the downhole components sensing the high frequency signal from the signal received over the power cable at the downhole components.

13. The system of claim 12, wherein the surface equipment further comprises:

a modulator generating an electrical signal having a current or voltage modulated by a modulation technique selected from frequency modulation, amplitude modulation, frequency shift key modulation, and phase shift key modulation.

14. The system of claim 12, wherein the surface equipment includes a driver transmitting control signals from the surface equipment to the downhole components, the downhole components further comprising:

a driver transmitting data from the downhole components to the surface equipment.

15. The system of claim 12, further comprising:

a first filter within the downhole components filtering the high frequency signal from the three phase power within the signal received over the power cable; and

a second filter within the downhole components filtering the three phase power from the high frequency signal within the signal received over the power cable.

16. The system of claim 15, further comprising:

conductors transmitting the three phase power from the first filter to an electrical submersible pump motor;

a bridge rectifier connected to the second filter rectifying the high frequency signal to provide operational power to selected downhole components; and

a modulator connected to the second filter and selectively connecting a load between a first conductor connected to a first three phase power cable conductor and a second conductor connected to a second three phase power cable conductor to encode data within the high frequency signal.

17. The system of claim 16, further comprising:

a third filter within the surface equipment connected to the power cable and filtering the three phase power from the high frequency signal within the signal received over the power cable; and

a demodulator within the surface equipment connected to the third filter and subtracting the filtered high frequency signal received on a first conductor connected to the first three phase power cable conductor from the filtered high frequency signal received on a second conductor connected to the second three phase power cable conductor to extract data from the filtered high frequency signal.