Method and apparatus for transmitting and receiving data to and from a downhole tool

• US 7,190,280 B2
• Filed: 06/17/2003
• Issued: 03/13/2007
• Est. Priority Date: 01/31/2003
• Status: Active Grant

• Current Assignee: IntelliServ, LLC (NOV, Inc.)
• Original Assignee: Intelliserv, Inc. (NOV, Inc.)
• Inventors: Hall, David R., Fox, Joe
• Primary Examiner(s): Bagnell; David
• Assistant Examiner(s): Stephenson; Daniel P
• Application Number:
  US10/250,245
• Publication Number:
  US 20040150532A1
• Time in Patent Office: 1,365 Days
• Field of Search: 175/40, 175/104, 340/854.9, 340/855.1, 340/855.3, 340/854.3, 340/854.8
• US Class Current: 340/855.1
• 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 15/003 with sealing rings
• CPC Class Codes: F16L 15/009 with axial sealings having at least one plastically deformable sealing surface with sealing rings F16L15/008
• CPC Class Codes: H01F 2038/143 for signals
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01R 13/523 for use under water
• CPC Class Codes: H01R 13/6633 with inductive component, e.g. transformer
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 24/566 Hollow cables
• CPC Class Codes: H01R 9/05 for coaxial cables

Abstract

A transmission line network system for transmitting and/or receiving data from a downhole tool. The invention is achieved by providing one or more transceiving elements, preferably rings, at either end of a downhole tool. A conduit containing a coaxial cable capable of communicating an electrical signal is attached to the transceiving element and extends through a central bore of the downhole tool and through the central bore of any tool intermediate the first transceiving element and a second transceiving element. Upon receiving an electrical signal from the cable, the second transceiving element may convert such signal to a magnetic field. The magnetic field may be detected by a third transceiving element in close proximity to the second transceiving element. In this manner, many different tools may be included in a downhole transmission network without requiring substantial modification, if any, of any particular tool.

Claims

1. A system for transceiving data between downhole tools located on a drill string, said system comprising:

a drill string comprising a proximal end, a distal end, and a length;

a first cable substantially retained by a central bore of said drill string to transmit a signal carrying first information between said proximal end and said distal end over a first portion of said length, said first portion of said length comprising a plurality of downhole tools, wherein said plurality of downhole tools are not configured to convey said signal along their lengths;

a first transmission element coupled to said first cable to convert said signal to a magnetic field;

a second transmission element proximate said first transmission element to receive said magnetic field and convert said magnetic field into a second signal carrying said first information;

a second cable coupled to said second transmission element and substantially retained by a central bore of said drill string to transmit said second signal between said proximal end and said distal end over a second portion of said length, said second portion of said length comprising a plurality of downhole tools, wherein said plurality of downhole tools are not configured to convey said signal along their lengths;

each of said first and said second transmission elements comprises;

a housing comprising a ring having a substantially U-shaped trough;

said ring further comprising circumferential ridges integrated into an outer surface of said ring to enhance connection of said ring into one of the downhole tools;

a magnetically conductive trough disposed within said housing;

an electrically conductive coil disposed within said trough; and

a connector coupled to said cable and to at least one of said conductive element and said housing.

2. The system of claim 1, wherein each of said downhole tools comprises a first end and a second end, wherein said first end of a first downhole tool is connected to said second end of a second downhole tool at a torque producing interface.

3. The system of claim 2, wherein said first transmission element is coupled to said first end of said first downhole tool at said torque producing interface, and wherein said second transmission element is coupled to said second end of said second downhole tool at said torque producing interface.

4. The system of claim 1, wherein said drill string further comprises a plurality of downhole tools connected at a plurality of torque producing interfaces, each said downhole tool comprising:

a cylindrical body having an outer wall and a central bore;

a first end attached to said body, said first end having a first torque producing surface, a second torque producing surface, and external tapered threads; and

a second end attached to said body opposite said first end, said second end having a first torque producing plane, a second torque producing plane, and internal tapered threads.

5. The system of claim 4, wherein said first end integrates said first transmission element at said second torque producing surface.

6. The system of claim 4, wherein said first end further comprises a first annular recess integrated into said second torque producing surface for receiving said first transmission element.

7. The system of claim 6, wherein said first transmission element is retained in said first annular recess by a press fit.

8. The system of claim 6, wherein said cylindrical body further comprises a first channel having a first opening and a second opening, said first channel substantially extending from said second torque producing surface to said central bore.

9. The system of claim 8, wherein said first opening substantially adjoins said first annular recess.

10. The system of claim 4, wherein said second end integrates said second transmission element at said second torque producing plane.

11. The system of claim 4, wherein said second end further comprises a second annular recess integrated into said second torque producing plane for receiving said second transmission element.

12. The system of claim 11, wherein said second transmission element is retained in said second annular recess by a press fit.

13. The system of claim 11, wherein said cylindrical body further comprises a second channel having a first hole and a second hole, said second channel substantially extending from said second torque producing plane to said central bore.

14. The system of claim 13, wherein said second opening substantially adjoins said second annular recess.

15. The system of claim 4, said cylindrical body further comprising at least one retaining channel at least partially integrated into said outer wall for retaining said cable.

16. The system of claim 15, wherein said cable is retained in said retaining channel by tension.

17. The system of claim 4, wherein said downhole tool is selected from the group consisting of casings, drill pipe, heavy-weight drill pipe, drill collars, drill bit subs, transmission links, reamers, stabilizers, motors, turbines, mud hammers, Jars, Kellys, blow-out preventers, steering subs and drill bits.

18. The system of claim 1, wherein each of said first and said second cables comprises:

an outer tube;

a conductive core disposed within said outer tube; and

a dielectric sheath surrounding said conductive core.

19. The system of claim 18, further comprising a conductive sheath disposed between said outer tube and said dielectric sheath.

20. The system of claim 18, wherein said outer tube comprises rigid metal.

21. The system of claim 20, wherein said outer tube comprises stainless steel.

22. The system of claim 1, wherein each of said first and said second transmission elements further comprise an adhesive disposed between said housing, said trough and said conductive element for retaining said trough and said conductive element in a fixed relationship relative to said housing and for resisting abrasion of said transmission elements.

23. The system of claim 22, wherein said adhesive comprises at least one of silica, aluminum oxide and urethane.

24. The system of claim 1, wherein said ring is steel.

25. The system of claim 1, wherein said trough comprises ferrite.

26. The system of claim 25, wherein said ferrite is segmented.

27. The system of claim 1, wherein said conductive element comprises a loop of wire.

28. The system of claim 27, wherein said wire is copper.

29. The system of claim 27, wherein said wire is silver plated, copper clad steel.

30. The system of claim 27, wherein said wire is insulated.

31. The system of claim 30, wherein said wire is insulated with at least one of high density polyethylene and polymerized tetrafluoroethane.

32. A system for transceiving data between downhole tools located on a drill string, said system comprising:

a drill string comprising a proximal end, a distal end, and a length;

a first cable substantially retained by a central bore of said drill string to transmit a signal carrying first information between said proximal end and said distal end over a first portion of said length, said first portion of said length comprising a plurality of downhole tools, wherein said plurality of downhole tools are not configured to convey said signal along their lengths;

a first transmission element coupled to said first cable to convert said signal to a magnetic field;

a second transmission element proximate said first transmission element to receive said magnetic field and convert said magnetic field into a second signal carrying said first information;

a second cable coupled to said second transmission element and substantially retained by a central bore of said drill string to transmit said second signal between said proximal end and said distal end over a second portion of said length, said second portion of said length comprising a plurality of downhole tools, wherein said plurality of downhole tools are not configured to convey said signal along their lengths;

each of said first and said second transmission elements comprises;

a housing;

a magnetically conductive trough disposed within said housing;

an electrically conductive coil disposed within said trough; and

a connector coupled to said cable and to said conductive element and said housing wherein said connector further comprises a first contact and a second contact.

33. The system of claim 32, wherein said first contact adjoins said connector to said conductive element.

34. The system of claim 32, wherein said second contact adjoins said connector to said housing.

35. A data transmission network for transceiving information between downhole tools located on a drill string, the data transmission network comprising:

a first downhole tool having a first proximal end, a first distal end and a first central bore;

a second downhole tool having a second proximal end, a second distal end and a second central bore;

at least one intermediate downhole tool not configured to convey a signal along its length, wherein each said at least one intermediate downhole tool is located intermediate said first downhole tool and said second downhole tool, each said at least one intermediate downhole tool having an intermediate central bore, an intermediate proximal end and an intermediate distal end;

a first cable to transceive a first electrical signal carrying first information between ground level and said first downhole tool, wherein a portion of said first cable is disposed within said first central bore;

a second cable to transceive a second electrical signal carrying said first information between one of said at least one intermediate downhole tool and said second downhole tool, wherein a portion of said second cable is disposed within said intermediate central bore;

a first transmission element mounted proximate said first distal end and coupled to said first cable to transduce said first electrical signal to a magnetic signal; and

a second transmission element mounted proximate said intermediate proximal end and coupled to said second cable to transduce said magnetic signal to said second electrical signal and to transceive said second electrical signal along said second cable wherein each of said first and said second transmission elements comprises;

a housing;

a magnetically conductive trough disposed within said housing;

an electrically conductive coil disposed within said trough; and

a connector coupled to said cable and to at least one of said conductive coil and said housing, said housing further comprises a ring having a substantially U-shaped trough and further comprising circumferential ridges integrated into an outer surface of said ring to facilitate retention of said ring by at least one of said first downhole tool and said second downhole tool.

36. The network of claim 35, wherein each of said first proximal end and said second proximal end further comprises a first torque producing surface, a second torque producing surface, and external tapered threads attached to each of said first and second proximal ends.

37. The network of claim 36, wherein each of said first distal end and said second distal end further comprises a first torque producing plane, a second torque producing plane, and internal tapered threads attached to each of said first and second distal ends.

38. The network of claim 37, wherein at least one of said first and said second proximal ends integrates said first transmission element into at least one of said second torque producing surfaces.

39. The network of claim 37, wherein at least one of said first and said second proximal ends further comprises a first annular recess integrated into said second torque producing surface for receiving said first transmission element.

40. The network of claim 39, wherein said first transmission element is retained in said first annular recess by a press fit.

41. The network of claim 39, wherein said cylindrical body further comprises a first channel having a first opening and a second opening, said first channel substantially extending from said second torque producing surface to said central bore.

42. The network of claim 41, wherein said first opening substantially adjoins said first annular recess.

43. The network of claim 37, wherein at least one of said first and said second distal ends integrates said second transmission element into at least one of said second torque producing planes.

44. The network of claim 37, wherein at least one of said first and said second distal ends further comprises a second annular recess integrated into at least one of said second torque producing planes for receiving said second transmission element.

45. The network of claim 44, wherein said second transmission element is retained in said second annular recess by a press fit.

46. The network of claim 44, wherein said cylindrical body further comprises a second channel having a first hole and a second hole, said second channel substantially extending from said second torque producing plane to said central bore.

47. The network of claim 46, wherein said second opening substantially adjoins said second annular recess.

48. The network of claim 35, said cylindrical body further comprising at least one retaining channel at least partially integrated into an outer wall of the cylindrical body for retaining said cable.

49. The network of claim 48, wherein said cable is retained in said retaining channel by tension.

50. The network of claim 35, wherein each of said first and said second downhole tools is selected from the group consisting of casings, drill pipe, heavy-weight drill pipe, drill collars, drill bit subs, transmission links, reamers, stabilizers, motors, turbines, mud hammers, Jars, Kellys, blow-out preventers, steering subs and drill bits.

51. The network of claim 35, wherein each of said first and said second cables comprises:

an outer tube;

a conductive core disposed within said outer tube; and

a dielectric sheath surrounding said conductive core.

52. The network of claim 51, further comprising a conductive sheath disposed between said outer tube and said dielectric sheath.

53. The network of claim 51, wherein said outer tube comprises rigid metal.

54. The network of claim 53, wherein said outer tube comprises stainless steel.

55. The network of claim 35, wherein each of said first and said second transmission elements further comprises an adhesive disposed between at least two of said housing, said trough and said conductive coil for retaining said trough and said conductive coil in a fixed relationship relative to said housing and for resisting abrasion of said housing, said trough and said conductive coil.

56. The network of claim 55, wherein said adhesive comprises at least one of silica, aluminum oxide and urethane.

57. The network of claim 35, wherein said ring is steel.

58. The network of claim 35, wherein said trough comprises ferrite.

59. The network of claim 58, wherein said ferrite is segmented.

60. The network of claim 35, wherein said conductive coil comprises wire.

61. The conductive coil of claim 60, wherein said wire is copper.

62. The network of claim 60, wherein said wire is silver plated, copper clad steel.

63. The network of claim 60, wherein said wire is insulated.

64. The network of claim 63, wherein said insulation comprises at least one of high density polyethylene and polymerized tetrafluoroethane.

65. A data transmission network for transceiving information between downhole tools located on a drill string, the data transmission network comprising:

a first downhole tool having a first proximal end, a first distal end and a first central bore;

a second downhole tool having a second proximal end, a second distal end and a second central bore;

at least one intermediate downhole tool not configured to convey a signal along its length, wherein each said at least one intermediate downhole tool is located intermediate said first downhole tool and said second downhole tool, each said at least one intermediate downhole tool having an intermediate central bore, an intermediate proximal end and an intermediate distal end;

a first cable to transceive a first electrical signal carrying first information between ground level and said first downhole tool, wherein a portion of said first cable is disposed within said first central bore;

a second cable to transceive a second electrical signal carrying said first information between one of said at least one intermediate downhole tool and said second downhole tool, wherein a portion of said second cable is disposed within said intermediate central bore;

a first transmission element mounted proximate said first distal end and coupled to said first cable to transduce said first electrical signal to a magnetic signal; and

a second transmission element mounted proximate said intermediate proximal end and coupled to said second cable to transduce said magnetic signal to said second electrical signal and to transceive said second electrical signal along said second cable wherein each of said first and said second transmission elements comprises;

a housing;

a magnetically conductive trough disposed within said housing;

an electrically conductive coil disposed within said trough; and

a connector coupled to said cable and to said conductive coil and said housing, and wherein said connector further comprises a first contact and a second contact.

66. The network of claim 65, wherein said first contact adjoins said connector to said conductive coil.

67. The network of claim 65, wherein said second contact adjoins said connector to said housing.