Reliable wired-pipe data transmission system

• US 8,941,384 B2
• Filed: 12/23/2009
• Issued: 01/27/2015
• Est. Priority Date: 01/02/2009
• Status: Active Grant

• Current Assignee: Nextstream Wired Pipe, LLC
• Original Assignee: Martin Scientific LLC
• Inventors: Prammer, Manfred G.
• Primary Examiner(s): Nguyen, Vinh
• Assistant Examiner(s): RIOS RUSSO, RAUL J
• Application Number:
  US13/142,612
• Publication Number:
  US 20120176138A1
• Time in Patent Office: 1,861 Days
• Field of Search: 324/642, 324333-375
• US Class Current: 324/338
• 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 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: E21B 47/12 Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
• CPC Class Codes: E21B 47/13 by electromagnetic energy, e.g. radio frequency
• CPC Class Codes: G01V 2003/084 Sources
• CPC Class Codes: G01V 3/08 operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices with electromagnetic waves G01V3/12
• CPC Class Codes: G01V 3/18 specially adapted for well-logging
• CPC Class Codes: G01V 3/26 operating with magnetic or electric fields produced or modified either by the surrounding earth formation or by the detecting device with electromagnetic waves G01V3/30
• CPC Class Codes: G01V 3/28 using induction coils

Abstract

A high-frequency data and/or power transmission system suitable for downhole use including signal/power couplers, transmission line segments and signal repeaters. Signals and power are/is transmitted between couplers and/or between couplers and repeaters by means of electromagnetic resonance coupling. In at least a portion of the system, the transmission line segments form parallel data paths and the repeaters provide crossover capability between the data/power paths, thereby significantly improving reliability. The invention also includes methods of transmitting data and/or distributing high-frequency power through a downhole transmission system including multiple data/power paths and multiple crossovers wherein a fault location in one data/power path is bypassed by routing data and/or power to a parallel data/power path by means of electromagnetic resonance coupling.

Claims

1. A downhole signal and/or power transmission system for providing communications and/or power along a drill string of interconnected downhole components, comprising:

a plurality of downhole components, at least one of said downhole components comprising;

a first end containing a pin electromagnetic coupler adapted to provide resonant coupling, said first end mechanically interconnecting with an end of a first adjacent downhole component containing a box electromagnetic coupler; and

a second end containing a box electromagnetic coupler adapted to provide resonant coupling, said second end mechanically interconnecting with an end of a second adjacent downhole component containing a pin electromagnetic coupler,

wherein signals and/or power are exchanged among said downhole components by electromagnetic resonant coupling between pin electromagnetic couplers and box electromagnetic couplers of adjacent downhole components, said electromagnetic resonant coupling occurring at frequencies within the VHF or UHF bands between 30 MHz and 3 GHz.

2. A downhole transmission system as in claim 1, wherein said electromagnetic couplers are constructed from non-magnetic materials.

3. A downhole transmission system as in claim 1, further comprising at least one signal repeater that is electromagnetically coupled to the box electromagnetic coupler in said second end of said downhole component and is electromagnetically coupled to said end of said second adjacent downhole component.

4. A downhole transmission system as in claim 1, wherein said at least one downhole component further comprises a plurality of electric conductors connecting the pin electromagnetic coupler in the first end to the box electromagnetic coupler in the second end through said downhole component so as to form a plurality of parallel data paths between said pin electromagnetic coupler and said box electromagnetic coupler.

5. A downhole transmission system as in claim 4, wherein an electric fault in one of said data paths is substantially decoupled by weak off-resonance coupling from the remainder of said plurality of said data paths and wherein said electric fault is substantially bypassed by means of electromagnetic coupling between said electromagnetic couplers.

6. A downhole transmission system as in claim 4, further comprising at least one signal repeater that is electromagnetically coupled to the box electromagnetic coupler in said second end of said downhole component and is electromagnetically coupled to said end of said second adjacent downhole component, wherein said at least one signal repeater provides crossover capability between parallel data paths.

7. A downhole transmission system as in claim 3, wherein the second end of said downhole component houses said signal repeater.

8. A downhole transmission system as in claim 3, comprising a plurality of signal repeaters and at least one processor, wherein said processor:

receives message packets modulated on high-frequency signals;

detects faulty message packets; and

transmits correct message packets by modulating high-frequency signals with information.

9. A downhole transmission system as in claim 8, wherein at least one of said repeaters houses at least one of said processors.

10. A downhole transmission system as in claim 8, wherein said at least one processor is powered by said transmitted power.

11. A downhole transmission system as in claim 3, wherein said at least one signal repeater passively passes said signals and/or power.

12. A downhole transmission system as in claim 3, wherein said interconnected downhole components have rotary connections and at least some of said rotary connections are adapted to accept said at least one signal repeater.

13. A downhole transmission system as in claim 12, wherein said rotary connections are of the double-shouldered type.

14. A downhole transmission system as in claim 1, wherein said signals having information modulated thereon.

15. A downhole transmission system as in claim 1, wherein said downhole components comprise pipe joints, pup joints, crossover subs, communication subs, bottom hole assembly subs and/or repeater subs.

16. A downhole transmission system as in claim 1, wherein said pin electromagnetic coupler and said box electromagnetic coupler each comprises at least one substantially circular antenna and wherein said at least one antenna is placed in a substantially circular groove and wherein the remaining volume of said groove is filled with non-magnetic dielectric material.

17. A downhole transmission system as in claim 16, further comprising capacitors that relate the electrical length of each antenna to the length of the groove in which said at least one antenna is placed.

18. A downhole transmission system as in claim 1, wherein said pin electromagnetic coupler is separated from said end of said first adjacent downhole component by a first gap, said first gap containing electrically conductive or electrically insulating fluids;

and/or

wherein said box electromagnetic coupler is separated from said end of said second adjacent downhole component by a second gap, said second gap containing electrically conductive or electrically insulating fluids.

19. A downhole transmission system as in claim 3, wherein said at least one signal repeater is separated from said box electromagnetic coupler in said second end of said downhole component by a first gap, said first gap containing electrically conductive or electrically insulating fluids;

and/or

wherein said signal repeater is separated from said pin electromagnetic coupler in said pin end of said second adjacent downhole component by a second gap, said second gap containing electrically conductive or electrically insulating fluids.

20. A downhole transmission system as in claim 3, wherein said at least one repeater comprises a repeater box having a plurality of cavities adapted to accept electronic circuits and energy storage units.

21. A downhole transmission system as in claim 3, wherein at least one of said signal repeaters comprises a sensor circuit including a sensor, conditioning circuitry, an analog/digital converter, a processor, and power-switching circuitry, wherein said sensor circuit is adapted to take sensor readings.

22. A downhole transmission system as in claim 21, wherein said sensor acquires sensor data comprising local acceleration data, vibration data, and/or shock data gathered along said drill string.

23. A downhole transmission system as in claim 3, wherein at least one of said signal repeaters comprises a solenoidal coil, a permanent magnet that is loosely suspended within the solenoidal coil so as to move relative to the solenoidal coil as the drill string vibrates in the longitudinal direction and to thereby induce voltages in the solenoidal coil, a power conditioning circuit that captures the induced voltages, and a storage capacitor that stores captured induced energy.

45. A downhole transmission system as in claim 4, wherein said plurality of electric conductors comprises a coaxial cable.

46. A downhole transmission system as in claim 4, wherein said plurality of electric conductors comprises a wire buried in pipe coating.

24. A signal and/or power coupling element for exchanging communications signals and/or power between drill string components and/or between elements of said drill string components, comprising:

a first electromagnetic coupler mounted on a first of said components or elements and adapted to provide resonant coupling; and

a second electromagnetic coupler mounted on a second of said components or elements and adapted to provide resonant coupling;

wherein said communications signals and/or power are exchanged between said components or elements by electromagnetic resonant coupling between said first and second electromagnetic couplers, said electromagnetic resonant coupling occurring at frequencies within the VHF or UHF bands between 30 MHz and 3 GHz.

25. A coupling element as in claim 24, wherein said electromagnetic couplers are constructed from non-magnetic materials.

26. A coupling element as in claim 24, wherein said components or elements are rotatable and/or translatable with respect to each other while said communication signals and/or said power are being exchanged.

27. A coupling element as in claim 24, wherein said first electromagnetic coupler and said second electromagnetic coupler each comprises at least one substantially circular antenna placed in a substantially circular groove that is filled with non-magnetic material.

28. A coupling element as in claim 27, further comprising capacitors that relate the electrical length of each antenna to the length of the groove in which said at least one antenna is placed.

29. A method of providing communications along a drill string of downhole components comprising a plurality of interconnected downhole components having rotary connections, comprising the steps of:

generating high-frequency signals having information modulated thereon;

providing a plurality of signal repeaters spaced along said drill string of downhole components;

providing at least one downhole component having;

a first end containing a pin electromagnetic coupler adapted to provide resonant coupling, said first end mechanically interconnecting with an end of a first adjacent downhole component containing a box electromagnetic coupler,

a second end containing a box electromagnetic coupler adapted to provide resonant coupling, said second end mechanically interconnecting with an end of a second adjacent downhole component containing a pin electromagnetic coupler, and

at least one conductor connecting the pin electromagnetic coupler in the first end to the box electromagnetic coupler in the second end through said downhole components so as to form at least one data path between said pin electromagnetic coupler and said box electromagnetic coupler;

electromagnetically coupling said high-frequency signals from one of said first and second adjacent downhole components to said downhole component and/or to said signal repeater through said pin and/or box electromagnetic couplers by means of electromagnetic resonant coupling;

transmitting said high-frequency signals through said at least one data path of said downhole component to the other end of said downhole component; and

electromagnetically coupling said high-frequency signals from said other end of said downhole component and/or from one of said signal repeaters to the other of said first and second adjacent downhole components through said pin and/or box electromagnetic couplers by means of electromagnetic resonant coupling, said electromagnetic resonant coupling occurring at frequencies within the VHF or UHF bands between 30 MHz and 3 GHz.

30. A method as in claim 29, wherein said pin and box electromagnetic couplers are constructed from non-magnetic materials.

31. A method as in claim 29, further comprising the step of providing a plurality of conductors connecting said pin electromagnetic coupler in said first end to said box electromagnetic coupler in said second end through said at least one downhole component so as to form a plurality of parallel data paths between said pin electromagnetic coupler and said box electromagnetic coupler.

32. A method as in claim 31, further comprising the step of said at least one signal repeater crossing said high-frequency signals from one parallel data path to another parallel data path.

33. A method as in claim 29, further comprising the step of a sensor circuit of at least one of said signal repeaters taking sensor readings.

34. A method as in claim 33, wherein said sensor acquires sensor data comprising local acceleration data, vibration data, and/or shock data gathered along said drill string.

35. A method as in claim 29, further comprising the steps of inducing voltages in a solenoidal coil in response to vibration of the drill string and storing induced energy.

36. A method as in claim 29, further comprising directing a processor of at least one of said signal repeaters to process message packets, to discard and/or repair faulty packets, and to transmit correct and/or repaired message packets by generating and modulating at least one high-frequency signal.

37. A method as in claim 29, further comprising the steps of:

generating high-frequency power, electromagnetically coupling said high-frequency power to at least one of said signal repeaters, rectifying said coupled high-frequency power, and storing rectified energy.

47. A method as in claim 29, wherein said at least one conductor comprises a coaxial cable.

48. A method as in claim 29, wherein said at least one conductor comprises a wire buried in pipe coating.

38. A method of exchanging signals and/or power between drill string components and/or elements of said drill string components, comprising the steps of:

generating high-frequency signals having information modulated thereon and/or generating high-frequency power;

providing a first electromagnetic coupler adapted to provide resonant coupling, said first coupler being mounted on or in a first component or element;

providing a second electromagnetic coupler adapted to provide resonant coupling, said second coupler being mounted on or in a second component or element; and

electromagnetically coupling said high-frequency signals and/or said high-frequency power from said first electromagnetic coupler to said second electromagnetic coupler by means of electromagnetic resonant coupling between said first and second electromagnetic couplers, said electromagnetic resonant coupling occurring at frequencies within the VHF or UHF bands between 30 MHz and 3 GHz.

39. A method as in claim 38, wherein said first and second electromagnetic couplers are constructed from non-magnetic materials.

40. A method as in claim 38, further comprising the step of providing a gap between said first and second electromagnetic coupler, said gap accommodating fluids that may be electrically conductive or electrically insulating.

41. A method as in claim 40, further providing for the ability of said drill string components and/or elements to rotate and/or to translate relative to each other while said signals and/or said power are exchanged between said drill string components and/or elements.

42. A method as in claim 38, further comprising the steps of providing at least one processor and at least one sensor circuit, and said sensor circuit taking sensor readings.

43. A method as in claim 42, further comprising the steps of processing said sensor readings into digital information and of modulating said high-frequency signals with said digital information.

44. A method as in claim 42, further comprising the steps of rectifying said coupled high-frequency power, storing rectified energy and powering said at least one processor and/or said at least one sensor circuit from said rectified energy.