Apparatus and methods for self-powered communication and sensor network

• US 8,284,075 B2
• Filed: 06/14/2004
• Issued: 10/09/2012
• Est. Priority Date: 06/13/2003
• Status: Active Grant

• Current Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Original Assignee: Baker Hughes Incorporated (Baker Hughes Company)
• Inventors: Fincher, Roger, Aronstam, Peter, Watkins, Larry, Gold, Randy
• Primary Examiner(s): WONG, ALBERT KANG
• Application Number:
  US10/867,304
• Publication Number:
  US 20050024231A1
• Time in Patent Office: 3,039 Days
• Field of Search: 290/1.R, 367/83, 336/132, 340/854.3
• US Class Current: 340/854.4
• CPC Class Codes: E21B 17/028 Electrical or electro-magnetic connections
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: E21B 47/135 using light waves, e.g. infrared or ultraviolet waves
• CPC Class Codes: E21B 47/14 using acoustic waves
• CPC Class Codes: E21B 47/16 through the drill string or casing , e.g. by torsional acoustic waves
• CPC Class Codes: G01V 11/002 Details, e.g. power supply systems for logging instruments, transmitting or recording data, specially adapted for well logging, also if the prospecting method is irrelevant means for transmitting well survey signals E21B47/12; signal transmission systems in general G08C; transmission in general H04B

Abstract

A measurement and communication system for use with a tubular string, comprises a tubular string having a plurality of self-powered, autonomous telemetry stations disposed at predetermined locations along the tubular string. Each autonomous telemetry station is adapted to receive at least one first signal and transmit at least one second signal related to the at least one first signal. Power is extracted from potential energy sources proximate each autonomous telemetry station. A method of communicating information along a tubular string comprises, disposing an autonomous telemetry station at predetermined locations along the tubular string. A preferred transmission path is autonomously determined at each of the autonomous telemetry stations. Information is transmitted along the tubular string according to the autonomously determined preferred path.

Claims

1. A communication system for use in a wellbore, comprising:

a tubular string in a wellbore, the tubular string having a plurality of sections connected by a plurality of connection joints to form the tubular string;

a transducer in a selected connection joint between two adjoining sections of the plurality of sections wherein the transducer is configured to receive a first signal from a preceding section and transmit a second signal related to the first signal over the selected connection joint into a succeeding section for transmission of the second signal to a transducer in a succeeding connection joint; and

a power source configured to generate electrical power to power the transducer, wherein the power source includes a rotor rotating a magnet proximate an electrically conductive coil in the selected connection joint, wherein the rotor is rotated by fluid flowing in the tubular string.

2. The system of claim 1, wherein the transducer further comprises:

a receiver coupled to the preceding section configured to receive the first signal from the preceding section;

a transmitter coupled to the succeeding section configured to transmit the second signal into the succeeding section; and

a controller having a processor and a memory, the controller configured to act according to programmed instructions to control the receiver and the transmitter according to a predetermined protocol.

3. The system of claim 1, wherein the power source is configured to utilize the fluid flowing in the tubular string to produce electrical power.

4. The system of claim 1, wherein a power source in another connection joint further comprises at least one of (i) a galvanic cell, (ii) a magneto-hydrodynamic generator, (iii) an eccentric mass generator, (iv) a rolling ball generator, (v) a thermoelectric generator, (vi) a fuel cell;

and (vii) a micro-turbine.

5. The system of claim 3, wherein a power source in another connection joint further comprises a piezoelectric element configured to react to pressure fluctuations caused by a pump pumping the fluid in the tubular string to generate electrical power.

6. The system of claim 5, wherein the piezoelectric element is embedded in an extension tube disposed a predetermined distance in the tubular string.

7. The system of claim 5, wherein the piezoelectric element is a piezo-polymer film attached along at least a portion of an extension tube wherein the extension tube is disposed in the tubular string.

8. The system of claim 5, wherein the piezoelectric element comprises a plurality of piezo-polymer film streamer elements configured to flutter in the flowing fluid for generating power.

9. The system of claim 2, wherein the power source includes an extension tube connected to the transducer, the extension tube extending a predetermined distance along a section of the tubular string.

10. The system of claim 9, further comprising a conductor embedded in the extension tube.

11. The system of claim 10, wherein the conductor is at least one of (i) an electrical conductor, (ii) an acoustical conductor, and (iii) an optical conductor.

12. The system of claim 9, wherein the extension tube is made from an elastomeric material.

13. The system of claim 12, wherein the extension tube is made from an expandable material selected from the group consisting of (i) a plastic, (ii) a fiber-reinforced composite, and (iii) a metal.

14. The system of claim 2, wherein the receiver and the transmitter are configured to communicate using at least one of (i) an acoustic transmission, (ii) a radio frequency transmission, (iii) a low frequency electromagnetic transmission, (iv) an optical transmission, and (v) an inductive back reflectance transmission.

15. The system of claim 1, wherein each transducer has a unique communication address.

16. The system of claim 1, further comprising a downhole tool configured to provide signals to be transmitted by the transducer to a surface controller.

17. The system of claim 16, wherein the downhole tool is chosen from a group consisting of (i) a measurement while drilling tool, and (ii) a logging while drilling tool.

18. The system of claim 2, wherein each of the transducers at each of the plurality of connection joints in the tubular string is configured to act according to programmed instructions to adaptively determine an acceptable communication path.

19. The system of claim 2, wherein each transducer is configured to provide a separate communication channel according to a predetermined protocol.

20. The system of claim 19, wherein the predetermined protocol directs each of the transducers to transmit one of (i) an independent data stream, (ii) a redundant data stream, and (iii) multiple channels for a single data stream.

21. The system of claim 2, further comprising a sensor associated with the transducer configured to detect a parameter of interest.

22. The system of claim 21, wherein the sensor is one of (i) a pressure sensor for measuring pressure of a flowing fluid inside the tubular string;

(ii) a pressure sensor for measuring pressure of a flowing fluid outside the tubular string;

(iii) a temperature sensor for measuring drill string temperatures;

(iv) a vibration sensor for measuring local drill string vibration;

(v) a sensor for measuring power source voltage;

(vi) a sensor for measuring strain in the tubular string proximate an autonomous telemetry station; and

(vii) a sensor for measuring a parameter of interest of a formation surrounding the borehole.

23. The system of claim 1, wherein the tubular string comprises at least one of (i) a drill string;

(ii) a casing string;

(iii) a production tubing string;

(iv) a water well;

(v) a pipeline;

(vi) an injection well; and

(vii) a monitoring well.

24. The system of claim 1, further comprising an instrumented sub disposed between at least two of the plurality of sections, the instrumented sub comprising a sensor for detecting at least one parameter of interest.

25. The system of claim 24, wherein the sensor comprises at least one of (i) a pressure sensor, (ii) a temperature sensor, (iii) a strain sensor, (iv) a chemical species sensor, (v) a fluid resistivity sensor, and (vi) a flow sensor.

26. The system of claim 12, wherein the extension tube has a relaxed outer diameter greater than an inner diameter of the tubular section.

27. The system of claim 26, wherein the extension tube is stretched a predetermined amount to reduce the outer diameter of the extension tube to allow installation of the extension tube in the tubular section.

28. A method for communicating along a jointed tubular in a borehole, comprising:

extending a tubular string in the borehole, the tubular string having a plurality of sections connected by a plurality of connection joints;

disposing a transducer in a selected connection joint between adjoining sections of the plurality of sections, wherein the transducer is configured to receive a first signal at one end of the selected connection joint from a transducer in a preceding section and transmit a second signal related to the first signal wirelessly directly into a succeeding section for transmission of the second signal to a transducer in a succeeding connection joint; and

using a power source to generate electrical power to power the transducer, wherein the power source includes a rotor rotating a magnet proximate an electrically conductive coil in the selected connection joint, wherein the rotor is rotated by fluid flowing in the tubular string.

29. The method of claim 28, wherein the transducer comprises:

a receiver for receiving the first signal;

a transmitter for transmitting the second signal; and

a controller having a processor and a memory, the controller acting according to programmed instructions to control the receiver and the transmitter according to a predetermined protocol.

30. The method of claim 28, wherein the power source uses the fluid flowing in the tubular string to generate electrical power.

31. The method of claim 29, wherein a power source in another connection joint further comprises at least one of (i) a galvanic cell, (ii) a magneto-hydrodynamic generator, (iii) an eccentric mass generator, (iv) a rolling ball generator, (v) a thermoelectric generator, (vi) a micro fuel cell;

and (vii) a micro-turbine.

32. The method of claim 30, wherein a power source in another connection joint uses a piezoelectric element to react to pressure fluctuations caused by a pump pumping the fluid in the tubular string to generate electrical power.

33. The method of claim 32, wherein the piezoelectric element is embedded in an extension tube disposed a predetermined distance in the tubular string.

34. The method of claim 32, wherein the piezoelectric element is a piezo-polymer film attached along at least a portion of an extension tube wherein the extension tube is disposed in the tubular string.

35. The method of claim 32, wherein the piezoelectric element comprises a plurality of piezo-polymer film streamer elements adapted to flutter in the flowing fluid for generating power.

36. The method of claim 29, wherein the power source includes an extension tube connected to the transducer, the extension tube extending a predetermined distance along a section of the tubular string.

37. The method of claim 36, wherein the extension tube further comprises a conductor embedded in the extension tube.

38. The method of claim 37, wherein the conductor is at least one of (i) an electrical conductor, (ii) an acoustical conductor, and (iii) an optical conductor.

39. The method of claim 36, wherein the extension tube is made from an elastomeric material.

40. The method of claim 36, wherein the extension tube is made from a plastic material.

41. The method of claim 29, wherein the receiver and the transmitter are adapted to communicate using at least one of (i) an acoustic transmission, (ii) a radio frequency transmission, (iii) a low frequency electromagnetic transmission, (iv) an optical transmission, and (v) an inductive back reflectance transmission.

42. The method of claim 29, wherein each transducer has a unique communication address.

43. The method of claim 29, further comprising a downhole tool and a surface controller.

44. The method of claim 43, wherein the downhole tool is chosen from the group consisting of (i) a measurement while drilling tool, and (ii) a logging while drilling tool.

45. The method of claim 29, wherein each of the transducers at each of the plurality of sections acts according to programmed instructions to adaptively determine which transducers provide an acceptable data path.

46. The method of claim 29, wherein the transducer comprises a plurality of transducers, each transducer providing a separate communication channel according to a predetermined protocol.

47. The method of claim 46, wherein the predetermined protocol directs each of the transducers to transmit one of (i) an independent data stream, (ii) a redundant data stream, and (iii) multiple channels for a single data stream.

48. The method of claim 28, further comprising a sensor associated with the transducer for detecting a parameter of interest.

49. The method of claim 48, wherein the sensor is one of (i) a pressure sensor for measuring pressure of a flowing fluid inside the tubular string;

(ii) a pressure sensor for measuring pressure of a flowing fluid outside the tubular string;

(iii) a temperature sensor for measuring drill string temperatures;

(iv) a vibration sensor for measuring local drill string vibration;

(v) a sensor for measuring power source voltage;

(vi) a sensor for measuring strain in the tubular string proximate an autonomous telemetry station; and

(vii) a sensor for measuring a parameter of interest of a formation surrounding the borehole.

50. The method of claim 28, wherein the tubular string comprises at least one of (i) a drill string;

(ii) a casing string;

(iii) a production tubing string;

(iv) a water well; and

(v) a pipeline.

51. The method of claim 39, wherein the extension tube has a relaxed outer diameter greater than an inner diameter of the tubular section.

52. The method of claim 51, further comprising stretching the extension tube a predetermined amount to reduce the outer diameter of the extension tube so as to allow installation of the extension tube in said tubular section.

53. A method for determining a drilling parameter distribution along a drilling tubular in a wellbore, comprising:

extending a tubular string in the borehole, the tubular string having a plurality of sections connected by a plurality of connection joints;

disposing a transducer in a selected connection joint between adjoining sections of the plurality of sections, wherein each transducer is configured to receive a first signal from a preceding section and transmit a second signal related to the first signal wirelessly directly into a succeeding section;

supplying electrical power to the transducer in the selected connection joint by a power source, wherein the power source includes a micro-turbine comprising a rotor rotating a magnet proximate within an electrically conductive coil in the selected connection joint, wherein the rotor is rotated by fluid flowing in the tubular string;

disposing a sensor for detecting a drilling parameter proximate to at least one of the transducers;

detecting the drilling parameter using the sensor; and

transmitting the detected drilling parameter to a surface processor.

54. The method of claim 53, wherein the drilling parameter is one of (i) drag on the drilling tubular;

(ii) torque on the drilling tubular;

(iii) drilling vibration level of the drilling tubular;

(iv) drilling whirl of the drilling tubular;

(v) annular drilling fluid pressure;

(vi) annular drilling fluid temperature; and

(vii) drilling fluid equivalent circulating density.

55. A communication system for use with a jointed tubular, comprising:

a tubular string, the tubular string having a plurality of sections connected by a plurality of connection joints;

a transducer disposed in each of the plurality of connection joints wherein each transducer is configured to receive a first signal from a preceding section and transmit a second signal related to the first signal wirelessly directed into a succeeding section; and

a power source for supplying power to at least one transducer in a selected connection joint, wherein the power source includes a rotor rotating a magnet proximate an electrically conductive coil in the selected connection joint, wherein the rotor is rotated by fluid flowing in the tubular string.

56. The system of claim 55, wherein the power source is configured to use the fluid flowing in the tubular string to generate electrical power.