Downhole data transmission system

• US 6,717,501 B2
• Filed: 07/18/2001
• Issued: 04/06/2004
• Est. Priority Date: 07/19/2000
• Status: Expired due to Term

• Current Assignee: IntelliServ, LLC (NOV, Inc.)
• Original Assignee: Novatek Engineering Incorporated
• Inventors: Hall, David R., Fox, Joe, Dahlgren, Scott, Hall, H. Tracy Jr., Pixton, David
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): Poker, Jennifer A
• Application Number:
  US09/909,469
• Publication Number:
  US 20020075114A1
• Time in Patent Office: 993 Days
• Field of Search: 336/132, 339/16, 339/15, 339/117, 439/194
• US Class Current: 336/132
• CPC Class Codes: E21B 17/003 with electrically conducting or insulating means E21B17/028 and E21B17/023 take precedence
• CPC Class Codes: E21B 17/0283 characterised by the coupling being contactless, e.g. inductive
• CPC Class Codes: E21B 17/0285 characterised by electrically insulating elements
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: F16L 15/001 with conical threads
• CPC Class Codes: F16L 25/01 specially adapted for realising electrical conduction between the two pipe ends of the joint or between parts thereof
• CPC Class Codes: H01R 13/533 Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure H01R13/52 takes precedence

Abstract

A system for transmitting data through a string of down-hole components. In accordance with one aspect, the system includes a plurality of downhole components, such as sections of pipe in a drill string. Each downhole component includes a pin end and a box end, with the pin end of one downhole component being adapted to be connected to the box end of another. Each pin end includes external threads and an internal pin face distal to the external threads. Each box end includes an internal shoulder face with internal threads distal to the internal shoulder face. The internal pin face and the internal shoulder face are aligned with and proximate each other when the pin end of the one component is threaded into a box end of the other component.

Claims

1. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each with a pin end and a box end, the pin end of one downhole component being adapted to be connected to the box end of an other downhole component, each pin end comprising external threads and an internal pin face distal to the external threads, said internal pin face being generally transverse to a longitudinal axis of the downhole component, and each box end comprising an internal shoulder face with internal threads distal to the internal shoulder face, said internal shoulder face being generally transverse to the longitudinal axis of the downhole component, and wherein the internal pin face and the internal shoulder face are aligned with and proximate each other when the pin end of the one component is threaded into a box end of the other component and wherein the internal pin face and the internal shoulder face of connected components are in a state of compression;

a first communication element located within a first recess formed in each internal pin face;

a second communication element located within a second recess formed in each internal shoulder face; and

a conductor in communication with and running between each first and second communication element in each component.

2. The system of claim 1 wherein the first and second communication elements are selected from the group consisting of inductive coils, acoustic transceivers, optical fiber couplers, and electrical contacts.

3. The system of claim 1 wherein the first and second communication elements are inductive coils.

4. The system of claim 1 wherein the internal pin face and the internal shoulder face of connected components are less than 0.03″

apart.

5. The system of claim 1 wherein the internal pin face and the internal shoulder face of connected components are touching.

6. The system of claim 1 wherein the first and second recesses are shaped and sized so as to allow the first and second communication elements to lie in the bottom of the respective recesses and be separated a distance from the top of the respective recesses, whereby the surface of the component wherein the recess is formed can be machined without damaging the communication element lying therein.

7. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each with a pin end and a box end, the pin end of one downhole component being adapted to be connected to the box end of an other downhole component, each pin end comprising external threads and an internal pin face distal to the external threads, said internal pin face being generally transverse to a longitudinal axis of the downhole component, and each box end comprising an internal shoulder face with internal threads distal to the internal shoulder face, said internal shoulder face being generally transverse to the longitudinal axis of the downhole component, and wherein the internal pin face and the internal shoulder face are aligned with and proximate each other when the pin end of the one component is threaded into a box end of the other component, and wherein the box end further comprises an external shoulder face distal to the internal threads and the pin end further comprises an external pin face and wherein the external shoulder face and the external pin face are aligned with and proximate each other when the pin end of the one component is threaded into the box end of the other component;

a first communication element located within a first recess formed in each internal pin face;

a second communication element located within a second recess formed in each internal shoulder face; and

a conductor in communication with and running between each first and second communication element in each component.

8. The system of claim 7 wherein the external pin face and the external shoulder face of connected components are in a state of compression and the respective pin face and the shoulder face are touching.

9. The system of claim 7 wherein the external pin face and the external shoulder face of connected components are in a state of compression and the respective pin face and the shoulder face are in a state of compression.

10. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each with a pin end and a box end, the pin end of one downhole component being adapted to be connected to the box end of an other downhole component, each pin end comprising external threads and an internal pin face distal to the external threads, said internal pin face being generally transverse to a longitudinal axis of the downhole component, and each box end comprising an internal shoulder face with internal threads distal to the internal shoulder face, said internal shoulder face being generally transverse to the longitudinal axis of the downhole component, and wherein the internal pin face and the internal shoulder face are aligned with and proximate each other when the pin end of the one component is threaded into a box end of the other component, and wherein the box end further comprises an external shoulder face distal to the internal threads and the pin end further comprises an external pin face and wherein the external shoulder face and the external pin face are aligned with and proximate each other when the pin end of the one component is threaded into the box end of the other component;

a first inductive coil located within a first recess formed in each internal pin face;

a second inductive coil located within a second recess formed in each internal shoulder face;

an electrical conductor in electrical communication with and running between each first and second coil in each component.

11. The system of claim 10 further comprising:

a first magnetically conductive, electrically insulating element within the first recess with the first inductive coil located therein, and which includes a first U-shaped trough with a bottom, first and second sides and an opening between the two sides;

a second magnetically conductive, electrically insulating element located within the second recess with the second inductive coil located therein, and which includes a second U-shaped trough with a bottom, first and second sides and an opening between the two sides;

the first and second troughs being configured so that the respective first and second sides and openings of the first and second troughs of connected components are substantially proximate to and substantially aligned with each other;

wherein a varying current applied to a first coil in one component generates a varying magnetic field in the first magnetically conductive, electrically insulating element, which varying magnetic field is conducted to and thereby produces a varying magnetic field in the second magnetically conductive, electrically insulating element of a connected component, which magnetic field thereby generates a varying electrical current in the second coil in the connected component, to thereby transmit a data signal.

12. The system of claim 11 wherein the magnetically conductive material is formed in segments within the first and second recesses, each segment interspersed with magnetically nonconductive material.

13. The system of claim 10 wherein the system is adapted to transmit data at a rate of at least 100 bits/second.

14. The system of claim 10 wherein the system is adapted to transmit data at a rate of at least 20,000 bits/second.

15. The system of claim 10 wherein the system is adapted to transmit data at a rate of at least 1,000,000 bits/second.

16. The system of claim 10 wherein the system is also used to transmit electrical power along the string of downhole components.

17. The system of claim 11 wherein the magnetically conductive, electrically insulating element has a magnetic permeability greater than 40.

18. The system of claim 11 wherein the magnetically conductive, electrically insulating element has a magnetic permeability greater than 100.

19. The system of claim 11 wherein the magnetically conductive, electrically insulating element comprises ferrite.

20. The system of claim 19 wherein the ferrite has a magnetic permeability greater than 40.

21. The system of claim 11 wherein the magnetically conductive, electrically insulating element comprises a magnetically soft metal in an electrically non-conductive structure.

22. The system if claim 21 wherein the structure is selected from the group consisting of a powdered magnetic material in an insulating matrix and a magnetic material between insulating layers.

23. The system of claim 11 wherein the openings in the first and second troughs are filled with an electrically insulating material, thereby encapsulating the first and second conductive coils lying therein.

24. The system of claim 21 wherein the electrically insulating material is selected from the group consisting of polyurethane, epoxy, silicone, rubber and phenolics, as well as combinations thereof.

25. The system of claim 10 wherein the first and second conductive coils are each made from a single loop of insulated wire.

26. The system of claim 10 wherein the first and second conductive coils are each made from at least two turns of insulated wire.

27. The system of claim 10 wherein the first and second recesses are shaped and sized so as to allow the first and second inductive coils to lie in the bottom of the respective recesses and be separated a distance from the top of the respective recesses, whereby the surface of the component wherein the recess is formed can be machined without damaging the inductive coil lying therein.

28. The system of claim 10 wherein the system is adapted to transmit data through at least 10 components powered only by the varying current supplied to one of the first conductive coils in one of the components.

29. The system of claim 10 wherein the system is adapted to transmit data through at least 20 components powered only by the varying current supplied to one of the first conductive coils in one of the components.

30. The system of claim 10 wherein the varying current supplied to the first conductive coil in the one component is driving a varying potential having a peak to peak value of between about 10 mV and about 20 V.

31. The system of claim 10 further comprising amplifying units in at least some of the components for amplifying the data signals.

32. The system of claim 31 wherein each of the amplifying units is powered by a battery.

33. The system of claim 32 wherein the amplifying units are provided in no more than 10 percent of the components in the string of downhole components.

34. The system of claim 10 wherein the power loss between two connected components is less than 15 percent.

35. The system of claim 10 wherein the current loss between two connected components is less than 5 percent.

36. The system of claim 10 wherein the ratio of the impedance of the electrical conductor to the impedance of the first and second electrically conductive coils is between 1:

2 and 2;

1.

37. The system of claim 10 wherein the magnetically conductive, electrically insulating element is formed in segments which are carried on a substrate, the substrate having a modulus of elasticity less than steel.

38. The system of claim 10 wherein the magnetically conductive, electrically insulating element is formed in segments, with a compressible material between otherwise adjacent segments.

39. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each downhole component with a first end and a second end, the first end of one downhole component being adapted to be connected to the second end of another downhole component;

a first magnetically conductive, electrically insulating element located proximate the first end of each downhole component, which includes a first U-shaped trough with a bottom, a first side and a second side and an opening between the two sides, with a magnetically conductive material being formed in segments, each segment interspersed with the magnetically nonconductive material;

a second magnetically conductive, electrically insulating element located proximate the second end of each downhole component, which includes a second U-shaped trough with a bottom, a first side and a second side and an opening between the two sides, with a magnetically conductive material being formed in segments, each segment interspersed with the magnetically nonconductive material;

the first and second troughs being configured so that the respective first and second sides and openings of the first and second troughs of connected components are substantially proximate to and substantially aligned with each other;

a first electrically conducting coil in each first trough;

a second electrically conducting coil in each second trough; and

an electrical conductor in electrical communication with and running between each first and second coil in each component;

wherein a varying current applied to a first coil in one component generates a varying magnetic field in the first magnetically conductive, electrically insulating element, which varying magnetic field is conducted to and thereby produces a varying magnetic field in the second magnetically conductive, electrically insulating element of a connected component, which magnetic field thereby generates a varying electrical current in the second coil in the connected component, to thereby transmit a data signal.

40. The system of claim 39 wherein the magnetically conductive, electrically insulating element has a magnetic permeability greater than 40.

41. The system of claim 39 wherein the magnetically conductive, electrically insulating element has a magnetic permeability greater than 100.

42. The system of claim 39 wherein the magnetically conductive, electrically insulating element comprises ferrite.

43. The system of claim 42 wherein the ferrite has a magnetic permeability greater than 40.

44. The system of claim 39 wherein the magnetically conductive, electrically insulating element comprises a magnetically soft metal in an electrically non-conductive structure.

45. The system if claim 44 wherein the structure is selected from the group consisting of a powdered magnetic material in an insulating matrix and a magnetic material between insulating layers.

46. The system of claim 39 wherein the openings in the first and second troughs are filled with an electrically insulating material, thereby encapsulating the first and second conductive coils lying therein.

47. The system of claim 46 wherein the electrically insulating material is selected from the group consisting of polyurethane, epoxy, silicone, rubber and phenolics, as well as combinations thereof.

48. The system of claim 39 wherein the first and second conductive coils are each made from a single loop of insulated wire.

49. The system of claim 39 wherein the first and second conductive coils are each made from at least two turns of insulated wire.

50. The system of claim 39 wherein the first and second troughs are shaped and sized so as to allow the first and second inductive coils to lie in the bottom of the respective troughs and be separated a distance from the top of the respective troughs, whereby the surface of the component wherein the trough is formed can be machined without damaging the inductive coil lying therein.

51. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each downhole component with a pin end and a box end, the pin end of one downhole component being adapted to be connected to the box end of an other downhole component, each pin end comprising external threads, and each box end comprising internal threads;

a first recess formed in each pin end;

a second recess formed in each box end, wherein the first and second recesses of connected components are substantially proximate and aligned with each other;

a first communication element located within each first recess;

a second communication element located within each second recess; and

a conductor in communication with and running between each first and second coil in each component;

wherein the first and second recesses are shaped and sized so as to allow the first and second communication elements to lie in the bottom of the respective recesses and be separated a distance from the top of the respective first and second recesses, whereby the surface of the component wherein the recess is formed can be machined without damaging the communication element lying therein.

52. The system of claim 51 wherein the distance is at least 0.01 inches.

53. The system of claim 51 wherein the distance is at least 0.06 inches.

54. The system of claim 51 wherein the first and second communication elements are selected from the group consisting of inductive coils, acoustic transceivers, optical fiber coupler, and electrical contacts.

55. The system of claim 51 wherein the first and second communication elements are inductive coils.

56. A system for transmitting data through a string of downhole components, the system comprising:

a plurality of downhole components, each downhole component with a pin end and a box end, the pin end of one downhole component being adapted to be connected to the box end of an other downhole component, each pin end comprising external threads and an internal pin face distal to the external threads, said internal pin face being generally transverse to a longitudinal axis of the downhole component, and each box end comprising an internal shoulder face with internal threads distal to the internal shoulder face, said internal shoulder face being generally transverse to the longitudinal axis of the downhole component, and wherein the internal pin face and the internal shoulder face are aligned with and proximate each other when the pin end of the one component is threaded into a box end of the other component

a first inductive coil located within a first recess formed in each internal pin face;

a first magnetically conductive, electrically insulating element within the first recess with the first inductive coil located therein;

a second inductive coil located within a second recess formed in each internal shoulder face;

a second magnetically conductive, electrically insulating element located within the second recess with the second inductive coil located therein;

an electrical conductor in electrical communication with and running between each first and second coil in each component;

wherein the magnetically conductive, electrically insulating element comprises a magnetically soft metal in an electrically non-conductive structure, and wherein a varying current applied to a first coil in one component generates a varying magnetic field in the first magnetically conductive, electrically insulating element, which varying magnetic field is conducted to and thereby produces a varying magnetic field in the second magnetically conductive, electrically insulating element of a connected component, which magnetic field thereby generates a varying electrical current in the second coil in the connected component, to thereby transmit a data signal.

57. The system of claim 56 wherein the magnetically conductive material is formed in segments within the first and second recesses, each segment interspersed with magnetically nonconductive material.

58. The system of claim 56 wherein the magnetically conductive material is ferrite.