DRILL STRING ADAPTER AND METHOD FOR INGROUND SIGNAL COUPLING

• US 20120217023A1
• Filed: 02/25/2011
• Published: 08/30/2012
• Est. Priority Date: 02/25/2011
• Status: Active Grant

• Current Assignee: Merlin Technologies Incorporated
• Original Assignee: Merlin Technologies Incorporated
• Inventors: Chau, Albert W., Medeiros, Benjamin John
• Granted Patent: US 8,695,727 B2
• Time in Patent Office: Days
• US Class Current: 166/380
• CPC Class Codes: E21B 17/003 with electrically conducting or insulating means E21B17/028 and E21B17/023 take precedence
• CPC Class Codes: E21B 17/0285 characterised by electrically insulating elements
• CPC Class Codes: E21B 17/042 Threaded
• CPC Class Codes: E21B 47/0232 at least one of the energy sources or one of the detectors being located on or above the ground surface
• CPC Class Codes: E21B 7/046 horizontal drilling drilling with mechanical conveying means E21B7/003
• CPC Class Codes: E21B 7/30 without earth removal

Abstract

A coupling adapter is insertable in at least one joint of a drill string as the drill string is extended from a drill rig. The coupling adapter includes an arrangement for receiving a data signal that is generated by an inground tool and for electromagnetically coupling the data signal onto at least a portion of the drill string that extends from the adapter to the drill rig such that at least some of the drill pipe sections cooperate as an electrical conductor for carrying the data signal to the drill rig. In another feature, a current transformer is resiliently supported to isolate the current transformer from mechanical shock and vibration that is produced by an inground operation that is performed using the drill string. In another feature, a drill string repeater is described.

Claims

1. In a system in which an inground tool is moved through the ground in a region for performing an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, an apparatus comprising:

a coupling adapter having an adapter body that is removably insertable at one of the joints as the drill string is extended to thereafter form part of the drill string and said coupling adapter includes;

an arrangement for receiving a data signal that is generated by the inground tool and for electromagnetically coupling the data signal, as an electrical signal, onto at least a portion of the drill string that extends from the adapter to the drill rig such that at least some of the drill pipe sections forming said portion of the drill string cooperate as an electrical conductor for carrying the data signal to the drill rig.

2. The apparatus of claim 1 wherein each drill pipe section includes a box fitting at one end and a pin fitting at an opposing end and wherein said adapter includes said box fitting at one end and said pin fitting at an opposite end.

3. The apparatus of claim 1 wherein said coupling adapter includes a current transformer in electrical communication with the inground tool for receiving the data signal and electromagnetically coupling the data signal at least onto said portion of the drill string and said coupling adapter further includes an adapter body assembly having an outer surface configuration that defines an annular recess for receiving said current transformer therein.

4. The apparatus of claim 3 wherein said current transformer includes an annular core.

5. The apparatus of claim 4 wherein said annular core is a split core.

6. The apparatus of claim 4 wherein said annular core is a tape wound core.

7. The apparatus of claim 3 wherein said adapter body assembly includes a main body that is configured for removable engagement with an extension body such that the main body defines said annular recess which receives the current transformer therein and which main body further receives a nonmagnetic ring in an installed position to cover said annular recess such that the nonmagnetic ring is captured between the main body and the extension body with the extension body engaged on the main body.

8. The apparatus of claim 7 wherein said nonmagnetic ring includes a cylindrical shape.

9. The apparatus of claim 7 wherein said nonmagnetic ring is a ceramic ring.

10. The apparatus of claim 9 wherein said ceramic ring is transformation toughened zirconium oxide ceramic.

11. The apparatus of claim 7 further comprising:

a support arrangement for resiliently supporting said current transformer on said main body such that the current transformer is isolated at least to some extent from a mechanical shock and vibration environment to which the housing is subjected responsive to said inground operation.

12. The apparatus of claim 1 wherein said adapter includes at least a first high pressure electrical connection assembly for a first electrical conductor by which the data signal is received from the inground tool and a current transformer for electromagnetically coupling the data signal from the first electrical conductor onto said portion of the drill string.

13. The apparatus of claim 12 wherein each drill pipe section defines a through passage to provide for a flow of drilling fluid through the drill string and wherein said adapter body includes a sidewall having a sidewall thickness and said sidewall defines (i) an internal passage which provides for said flow of drilling fluid through the adapter at any installed location of the adapter in said drill string, (ii) a stepped aperture that is defined through said sidewall thickness for receiving the first high pressure electrical connection assembly to form a pressure seal against passage of the drilling fluid under pressure from the internal passage through the stepped aperture with the first high pressure electrical connection assembly received by the first electrical conductor from said internal passage, and (iii) a sidewall passage extending from said current transformer to said stepped aperture within said sidewall thickness of the adapter body for housing a first electrical connection from the current transformer to said first high pressure electrical connection assembly.

14. The apparatus of claim 13 wherein said current transformer includes a first current transformer electrical lead that is received in said sidewall passage and extends to said first high pressure electrical connection assembly and said first high pressure electrical connection assembly electrically connects the first current transformer electrical lead to said first electrical conductor.

15. The apparatus of claim 12 wherein said adapter includes a coil serving as part of said current transformer and said coil having a winding in electrical communication with said first electrical conductor.

16. The apparatus of claim 15 wherein said adapter body is electrically conductive and said data signal is available from the inground tool on said first electrical conductor and a second electrical conductor and wherein said current transformer includes a first current transformer lead and a second current transformer lead with the first current transformer lead electrically connected to the first electrical conductor, and said second electrical conductor and said second current transformer lead are each electrically connected to the adapter body.

17. The apparatus of claim 15 wherein said data signal is available from the inground tool on said first electrical conductor and a second electrical conductor and said current transformer includes a first current transformer lead that is electrically connected to the first electrical conductor and a second current transformer lead that is electrically connected to the second electrical conductor and the first and second current transformer leads are electrically isolated from said adapter body.

18. The apparatus of claim 1 wherein said inground tool includes a housing that defines a housing cavity and said apparatus includes an electronics package that is received in said housing cavity and electrically connected to said arrangement for generating said data signal.

19. In a system in which an inground tool is moved through the ground in a region, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, a method comprising:

removably inserting a coupling adapter with an adapter body at one of the joints as the drill string is extended to thereafter form part of the drill string such that the coupling adapter receives a data signal that is generated by the inground tool and electromagnetically couples the data signal, as an electrical signal, onto at least some drill pipe sections which form a portion of the drill string that extends from the adapter to the drill rig cooperate as an electrical conductor for carrying the data signal to the drill rig.

20. The method of claim 19 wherein each drill pipe section includes a box fitting at one end and a pin fitting at an opposing end and including configuring said adapter to include said box fitting at one end and said pin fitting at an opposite end.

21. The method of claim 19 including configuring said adapter with at least a first high pressure electrical connection assembly for a first electrical conductor by which the data signal is received from the inground tool and arranging a current transformer for electromagnetically coupling the data signal from the first electrical conductor onto said portion of the drill string.

22. The method of claim 21 wherein each drill pipe section defines a through passage to provide for a flow of drilling fluid through the drill string and said method includes configuring said adapter body to include a sidewall having a sidewall thickness such that said sidewall defines (i) an internal passage which provides for said flow of drilling fluid through the adapter at any installed location of the adapter in said drill string, (ii) a stepped aperture that is defined through said sidewall thickness for receiving the first high pressure electrical connection assembly to form a pressure seal against passage of the drilling fluid under pressure from the internal passage through the stepped aperture with the first high pressure electrical connection assembly received by the first electrical conductor from said internal passage, and (iii) a sidewall passage extending from said current transformer to said stepped aperture within said sidewall thickness of the adapter body for housing a first electrical connection from the current transformer to said first high pressure electrical connection assembly.

23. The method of claim 22 wherein said current transformer includes a first current transformer electrical lead and wherein said method includes installing the first current transformer electrical lead in said sidewall passage to extend to said first high pressure electrical connection assembly such that said first high pressure electrical connection assembly electrically connects the first current transformer electrical lead to said first electrical conductor.

24. The method of claim 21 including configuring a coil having a winding to serve as said current transformer in said coupling adapter and connecting said winding in electrical communication with said first electrical conductor.

25. The method of claim 24 wherein said data signal is available from the inground tool on said first electrical conductor and a second electrical conductor, and wherein said current transformer includes a first current transformer lead and a second current transformer lead and said method includes forming said adapter body from an electrically conductive material, electrically connecting the first current transformer lead to the first electrical conductor, and electrically connecting each of said second electrical conductor and said second current transformer lead to the adapter body.

26. The method of claim 24 wherein said data signal is available from the inground tool on said first electrical conductor and a second electrical conductor and wherein said current transformer includes a first current transformer lead and a second current transformer lead and said method includes electrically connecting the first current transformer lead to the first electrical conductor, electrically connecting the second current transformer lead to the second electrical conductor, and maintaining electrical isolation of the first and second current transformer leads from said adapter body.

27. In a system in which an inground tool is moved through the ground in a region for performing an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, and said inground tool includes an electronics package for at least one of generating and receiving a data signal relating to the operation of the inground tool, an apparatus comprising:

a coupling adapter having an adapter body that is removably insertable at one of the joints as the drill string is extended to thereafter form part of the drill string and said coupling adapter includes;

a signal coupling arrangement for transferring the data signal between the inground tool and the drill rig at least in part by electromagnetically coupling the data signal between the coupling adapter and the drill string such that the data signal is electrically conducted as an electrical signal along at least a portion of the drill string that extends from the coupling adapter and at least some of the electrically conductive drill pipe sections forming said portion of the drill string cooperate as an electrical conductor for carrying the data signal.

28. The apparatus of claim 27 wherein said coupling adapter includes a current transformer in electrical communication with the inground tool for receiving the data signal and electromagnetically coupling the data signal at least onto said portion of the drill string and said coupling adapter further includes an adapter body assembly having an outer surface configuration that defines an annular recess for receiving said current transformer therein.

29. In a system in which an inground tool is moved through the ground in a region for performing an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, and said inground tool includes an electronics package for at least one of generating and receiving a data signal relating to the operation of the inground tool, a method comprising:

configuring a coupling adapter to include an adapter body that is removably insertable at one of the joints as the drill string is extended to thereafter form part of the drill string; and

transferring the data signal between the inground tool and the drill rig at least in part by electromagnetically coupling the data signal between the coupling adapter and the drill string such that the data signal is electrically conducted as an electrical signal along at least a portion of the drill string that extends between the coupling adapter and the drill rig and at least some of the electrically conductive drill pipe sections forming said portion of the drill string cooperate as an electrical conductor for carrying the data signal to the drill rig.

30. In a system in which an inground tool is moved through the ground in a region, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, an apparatus comprising:

an inground current transformer for receiving a data signal that is generated by the inground tool on a pair of electrical conductors and for electromagnetically coupling the data signal, as an electrical signal, onto at least a portion of the drill string that extends to the drill rig from the inground tool such that at least some of the drill pipe sections forming said portion of the drill string cooperate as an electrical conductor for carrying the data signal at least partially to the drill rig with the current transformer and said pair of electrical conductors in electrical isolation from the drill string.

31. The apparatus of claim 30 wherein said data signal is available from the inground tool on a first electrical conductor and a second electrical conductor and wherein said current transformer includes a first current transformer lead that is electrically connected to the first electrical conductor and a second current transformer lead that is electrically connected to the second electrical conductor and the first and second current transformer leads are electrically isolated from said drill string.

32. In a system in which an inground tool is moved through the ground in a region, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, a method comprising:

receiving a data signal that is generated by the inground tool on a pair of electrical conductors;

electromagnetically coupling the data signal, as an electrical signal, onto at least a portion of the drill string that extends to the drill rig from the inground tool using a current transformer such that at least some of the drill pipe sections forming said portion of the drill string cooperate as an electrical conductor for carrying the data signal to the drill rig; and

maintaining the current transformer and said pair of electrical conductors in electrical isolation from the drill string.

33. In a system in which an inground tool is moved through the ground in a region during an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, an apparatus comprising:

an electronics package that is configured for inground operation;

a current transformer configured for inductively coupled communication with said drill string as part of providing for communication between said electronics package and said drill rig on said drill string by using the drill string as an electrical conductor;

a housing having a housing body that is removably insertable at one of the joints as the drill string is extended to thereafter form part of the drill string and said housing is configured at least for receiving said current transformer with the current transformer inductively coupled to the drill string; and

a support arrangement for resiliently supporting said current transformer on said housing body such that the current transformer is isolated at least to some extent from a mechanical shock and vibration environment to which the housing is subjected responsive to said inground operation.

34. The apparatus of claim 33 wherein said current transformer is in electrical communication with said electronics package.

35. The apparatus of claim 33 wherein said current transformer includes an annular configuration and wherein said housing body defines an annular recess for receiving the current transformer and said current transformer is supported in said annular recess by the support arrangement.

36. The apparatus of claim 35 wherein said support arrangement includes a resilient foam which supports said current transformer in the annular recess.

37. The apparatus of claim 36 wherein said support arrangement includes one or more annular members formed from said resilient foam that are receivable in said annular recess to support said current transformer.

38. The apparatus of claim 35 wherein said support arrangement includes a plurality of resilient spacers that are distributed around a peripheral configuration of the current transformer for supporting the current transformer in the annular recess.

39. The apparatus of claim 38 wherein said support arrangement includes a resilient potting compound that is received in said annular recess between said resilient spacers for further supporting the current transformer in said annular recess to isolate the current transformer from the mechanical shock and vibration environment.

40. The apparatus of claim 35 wherein said support arrangement includes a resilient potting compound surrounding the current transformer in said annular recess to isolate the current transformer from the mechanical shock and vibration environment.

41. In a system in which an inground tool is moved through the ground in a region during an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, a method comprising:

providing an electronics package that is configured for inground operation;

configuring a current transformer for inductively coupled communication with said drill string as at least part of providing for communication between said electronics package and said drill rig on said drill string by using at least a portion of the drill string as an electrical conductor;

arranging a housing having a housing body for removable insertion at one of the joints as the drill string is extended to thereafter form part of the drill string and configuring said housing at least for receiving said current transformer with the current transformer inductively coupled to the drill string; and

resiliently supporting the current transformer on said housing body for said inductive coupling to the drill string such that the current transformer is isolated at least to some extent from a mechanical shock and vibration environment to which the housing is subjected responsive to said inground operation.

42. A repeater for use in a system in which an inground tool is moved through the ground in a region for performing an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, said repeater comprising:

a coupling adapter having an adapter body that is removably insertable at any selected one of the joints as the drill string is extended to thereafter form part of the drill string and said coupling adapter includes a signal coupling arrangement for providing bidirectional electromagnetic coupling between the coupling adapter and the drill string for receiving a data signal that is carried by electrical conduction by at least some of the electrically conductive drill pipe sections making up one portion of the drill string by electromagnetically coupling the data signal from the drill string to the coupling adapter as a received data signal;

an inground housing that is removably insertable at one of the joints as the drill string is extended to form part of the drill string with said coupling adapter and said inground housing defining a housing cavity; and

a repeater electronics package received in said housing cavity of the inground housing and which is in electrical communication with the signal coupling arrangement of the coupling adapter for producing a repeater signal based on the received data signal, but which is distinguishable from the received data signal and for providing the repeater signal to the signal coupling arrangement such that the signal coupling arrangement electromagnetically couples the repeater signal back to the drill string for transfer of the repeater signal as another electrical signal along the drill string such that the repeater signal is electrically conducted by at least some of the electrically conductive drill pipe sections making up a different portion of the drill string.

43. The repeater of claim 42 wherein said coupling adapter includes a current transformer in electrical communication with the inground tool for receiving the data signal and electromagnetically coupling the data signal at least onto said portion of the drill string and said coupling adapter further includes an adapter body assembly having an outer surface configuration that defines an annular recess for receiving said current transformer therein.

44. A method for use in a system in which an inground tool is moved through the ground in a region for performing an inground operation, said system including a drill rig and a drill string which extends between said inground tool and said drill rig and is configured for extension and retraction from said drill rig, said drill string being made up of a plurality of electrically conductive drill pipe sections, each of which includes a section length and each of which is configured for removable attachment to the inground tool at one joint and to one another at other joints that are formed between adjacent ones of the drill pipe sections such that the drill string includes a plurality of joints to facilitate the extension and retraction of the drill string by one section length at a time, said method comprising:

configuring a coupling adapter having an adapter body that is removably insertable at any selected one of said joints as the drill string is extended to thereafter form part of the drill string and arranging said coupling adapter to include a signal coupling arrangement for providing bidirectional electromagnetic coupling between the coupling adapter and the drill string for receiving a data signal that is carried by electrical conduction by at least some of the electrically conductive drill pipe sections making up one portion of the drill string by electromagnetically coupling the data signal from the drill string to the coupling adapter as a received data signal;

arranging an inground housing for removable insertion at one of the joints as the drill string is extended to form part of the drill string with said coupling adapter and defining a housing cavity within said inground housing; and

supporting a repeater electronics package in said housing cavity of the inground housing and connecting the repeater electronics package for electrical communication with the signal coupling arrangement of the coupling adapter for producing a repeater signal based on the received data signal, but which is distinguishable from the received data signal and for providing the repeater signal to the signal coupling arrangement such that the signal coupling arrangement electromagnetically couples the repeater signal back to the drill string for transfer of the repeater signal as another electrical signal along the drill string.

45. The method of claim 44 including configuring said coupling adapter with a current transformer in electrical communication with the repeater electronics package for electromagnetically receiving the data signal from the drill string and electromagnetically coupling the repeater signal back onto the drill string and said coupling adapter further includes an adapter body assembly having an outer surface configuration that defines an annular recess for receiving said current transformer therein.