Apparatus and methods for self-powered communication and sensor network

• US 20050024231A1
• Filed: 06/14/2004
• Published: 02/03/2005
• 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: Gold, Randy, Fincher, Roger, Aronstam, Peter, Watkins, Larry
• Granted Patent: US 8,284,075 B2
• Time in Patent Office: Days
• US Class Current: 340/854.400
• 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 with a jointed tubular, comprising:

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

an autonomous telemetry station disposed proximate each of said plurality of connection joints, said autonomous telemetry station adapted to receive a first signal and transmit a second signal related to said first signal.

2. The system of claim 1, wherein the autonomous telemetry station comprises:

a receiver for receiving said first signal;

a transmitter for transmitting said second signal;

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

a power source for supplying power to said autonomous telemetry station.

3. The system of claim 2, wherein the power source is adapted to extract energy from a downhole potential energy source proximate to said autonomous telemetry station.

4. The system of claim 3, wherein the downhole potential energy source comprises a fluid flowing in said tubular string.

5. The system of claim 3, wherein the downhole potential energy source comprises vibrational movement of said tubular string.

6. The system of claim 2, wherein the power source comprises at least one of (i) a piezoelectric element, (ii) a microturbine generator, (iii) a galvanic cell, (iv) a magneto-hydrodynamic generator, (v) an eccentric mass generator, (vi) a rolling ball generator, (vii) an electric battery, (viii) a thermoelectric generator, and (ix) a fuel cell.

7. The system of claim 4, wherein the power source comprises a piezoelectric element.

8. The system of claim 7, further comprising a protuberance inserted in said flowing fluid wherein said protuberance causes turbulent eddies in said flowing fluid, said turbulent eddies interacting with said piezoelectric element to generate electrical power.

9. The system of claim 8, wherein the piezoelectric element is embedded in an extension tube disposed a predetermined distance in said tubular string.

10. The system of claim 8, wherein the piezoelectric element is a piezo-polymer film attached along at least a portion of an extension tube wherein said extension tube is disposed in said tubular string.

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

12. The system of claim 2, further comprising an extension tube connected to said autonomous telemetry station, said extension tube extending a predetermined distance along a section of the tubular string.

13. The system of claim 12, further comprising a conductor embedded in said extension tube.

14. The system of claim 13, wherein the conductor is at least one of (i) an electrical conductor, (ii) an acoustical conductor, and (iii) an optical conductor.

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

16. 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.

17. The system of claim 2, 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, (v) an inductive back reflectance transmission.

18. The system of claim 1, wherein the autonomous telemetry station is a substantially torus shape and has a predetermined compliance such that said autonomous telemetry station is captured in each connection during assembly.

19. The system of claim 2, wherein each autonomous telemetry station has a unique communication address.

20. The system of claim 2, further comprising a downhole tool and a surface controller.

21. The system of claim 20, wherein the downhole tool is chosen from the group consisting of (i) a measurement while drilling tool, and (ii) a logging while drilling tool.

22. The system of claim 2, wherein each of the autonomous telemetry stations at each of the plurality of connections in the tubular string acts according to programmed instructions to adaptively determine an acceptable communication path.

23. The system of claim 2, wherein the autonomous telemetry station comprises a plurality of autonomous telemetry stations, each of said autonomous telemetry stations at a connection providing a separate communication channel according to a predetermined protocol.

24. The system of claim 23, wherein the predetermined protocol directs each of the autonomous telemetry modules to transmit one of (i) an independent data stream, (ii) a redundant data stream, and (iii) multiple channels for a single data stream.

25. The system of claim 2, further comprising a first sensor in said autonomous telemetry station for detecting a first parameter of interest.

26. The system of claim 25, wherein the first parameter of interest 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 the autonomous telemetry station; and

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

27. 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;

(iii) a water well;

(iv) a pipeline;

(v) an injection well; and

(vi) a monitoring well.

28. The system of claim 2, further comprising a waveguide attached to and extending substantially the length of each tubular section.

29. The system of claim 28, wherein the waveguide is an optical waveguide.

30. The system of claim 29, wherein the autonomous telemetry station further comprises an optical coupling material at least partially surrounding said autonomous telemetry station, and wherein said optical coupling material optically couples the optical waveguide on both sides of the autonomous telemetry station.

31. The system of claim 30, wherein the optical coupling material is transparent.

32. The system of claim 31, wherein the optical coupling material has a reflective material embedded therein.

33. The system of claim 30, wherein the optical coupling material is translucent.

34. The system of claim 30, wherein the optical coupling material is a viscous gel material.

35. The system of claim 28, wherein at least a portion of the waveguide comprises a magnetic material for adhering said waveguide to an internal diameter of the tubular section.

36. The system of claim 2, further comprising an instrumented sub disposed between at least two of said plurality of sections, said instrumented sub comprising a second sensor for detecting at least one second parameter of interest.

37. The system of claim 36, wherein the second 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 fluid flow sensor.

38. The system of claim 30, further comprising an optical fiber providing a redundant transmission path.

39. The system of claim 15, wherein the extension tube has a relaxed outer diameter greater than an inner diameter of the tubular section.

40. The system of claim 39, wherein the extension tube is stretched a predetermined amount to reduce the outer diameter of the extension tube to allow installation of said extension tube in said tubular section.

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

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

disposing an autonomous telemetry station proximate each of said plurality of connection joints, said autonomous telemetry station adapted to receive a first signal and transmit a second signal related to said first signal.

42. The method of claim 41, wherein the autonomous telemetry station comprises:

a receiver for receiving said at least one first signal;

a transmitter for transmitting said at least one second signal;

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

a power source for supplying power to said autonomous telemetry station.

43. The method of claim 41, wherein the power source is adapted to extract energy from a downhole potential energy source proximate to said autonomous telemetry station.

44. The method of claim 43, wherein the downhole potential energy source comprises a fluid flowing in said tubular string.

45. The method of claim 43, wherein the downhole potential energy source comprises vibrational movement of said tubular string.

46. The method of claim 42, wherein the power source comprises at least one of (i) a piezoelectric element, (ii) a microturbine generator, (iii) a galvanic cell, (iv) a magneto-hydrodynamic generator, (v) an eccentric mass generator, (vi) a rolling ball generator, (vii) an electrical battery, (viii) a thermoelectric generator, and (ix) a micro fuel cell.

47. The method of claim 44, wherein the power source comprises a piezoelectric element.

48. The method of claim 47, further comprising a protuberance inserted in said flowing fluid wherein said protuberance causes turbulent eddies in said flowing fluid, said turbulent eddies interacting with said piezoelectric element to generate electrical power.

49. The method of claim 48, wherein the piezoelectric element is embedded in an extension tube disposed a predetermined distance in said tubular string.

50. The method of claim 48, wherein the piezoelectric element is a piezo-polymer film attached along at least a portion of an extension tube wherein said extension tube is disposed in said tubular string.

51. The method of claim 48, wherein the piezoelectric element comprises a plurality of piezo-polymer film streamer elements adapted to flutter in the flowing fluid for generating power.

52. The method of claim 42, further comprising an extension tube connected to said autonomous telemetry station, said extension tube extending a predetermined distance along a section of the tubular string.

53. The method of claim 52, further comprising a conductor embedded in said extension tube.

54. The method of claim 53, wherein the conductor is at least one of (i) an electrical conductor, (ii) an acoustical conductor, and (iii) an optical conductor.

55. The method of claim 52, wherein the extension tube is made from an elastomer material

56. The method of claim 52, wherein the extension tube is made from a plastic material.

57. The method of claim 42, 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, (v) an inductive back reflectance transmission.

58. The method of claim 41, wherein the autonomous telemetry station is substantially torus shape and has a predetermined compliance such that said autonomous telemetry station is captured in each connection during assembly.

59. The method of claim 42, wherein each autonomous telemetry station has a unique communication address.

60. The method of claim 42, further comprising a downhole tool and a surface controller.

61. The method of claim 60, wherein the downhole tool is chosen from the group consisting of (i) a measurement while drilling tool, and (ii) a logging while drilling tool.

62. The method of claim 42, wherein each of the autonomous telemetry stations at each of the plurality of connections in the tubular string acts according to programmed instructions to adaptively determine which autonomous stations provide an acceptable data path.

63. The method of claim 42, wherein the autonomous telemetry station comprises a plurality of autonomous telemetry stations, each of said autonomous telemetry stations at a connection providing a separate communication channel according to a predetermined protocol.

64. The method of claim 63, wherein the predetermined protocol directs each of the autonomous telemetry modules to transmit one of (i) an independent data stream, (ii) a redundant data stream, and (iii) multiple channels for a single data stream.

65. The method of claim 42, further comprising a sensor in said autonomous telemetry station for detecting a parameter of interest.

66. The method of claim 65, wherein the parameter of interest 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 the autonomous telemetry station; and

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

67. The method of claim 41, wherein the tubular string comprises at least one of (i) a drill string;

(ii) a casing string;

(iii) a production tubing string;

(iii) a water well; and

(iv) a pipeline.

68. The method of claim 42, further comprising a waveguide attached to and extending substantially the length of each tubular section.

69. The method of claim 68, wherein the waveguide is an optical waveguide.

70. The method of claim 69, wherein the autonomous telemetry station further comprises an optical coupling at least partially surrounding said autonomous telemetry station, and wherein said optical coupling material optically couples the optical waveguide on both sides of the autonomous telemetry station.

71. The method of claim 70, wherein the optical coupling material is one of translucent and transparent.

72. The method of claim 70, wherein the optical coupling material has reflective material embedded therein.

73. The method of claim 70, wherein the optical coupling material is a viscous gel material.

74. The method of claim 55, wherein the extension tube has a relaxed outer diameter greater than an inner diameter of the tubular section.

75. The method of claim 74, stretching the extension tube a predetermined amount to reduce the outer diameter of the extension tube and allow installation of said extension tube in said tubular section.

76. A method for determining a drilling parameter distribution along a drilling tubular in a wellbore, comprising;

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

disposing an autonomous telemetry station proximate each of said plurality of connection joints, said autonomous telemetry station adapted to receive a first signal and transmit a second signal related to said first signal, said autonomous telemetry station having a sensor for detecting a drilling parameter proximate said autonomous telemetry station;

detecting the drilling parameter at each autonomous telemetry station; and

transmitting said drilling parameter to a surface processor for use by a drilling operator.

77. The method of claim 76, 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.

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

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

an autonomous telemetry station disposed proximate each of said plurality of connection joints, said autonomous telemetry station adapted to receive a first signal and transmit a second signal related to said first signal; and

a power source for supplying power to said autonomous telemetry station, wherein the power source is adapted to extract energy from a downhole potential energy source proximate to said autonomous telemetry station.

79. The system of claim 78, wherein the downhole potential energy source comprises a fluid flowing in said tubular string.

80. The system of claim 79, wherein the downhole potential energy source comprises vibrational movement of said tubular string.