U.S. patent application number 12/787103 was filed with the patent office on 2010-10-28 for surface communication apparatus and method for use with drill string telemetry.
This patent application is currently assigned to Intelliserv, LLC. Invention is credited to Randall P. LeBlanc, Qiming Li, Raghu Madhavan, Joseph Montero, David Santoso, Mark Sherman, John A. Thomas.
Application Number | 20100271233 12/787103 |
Document ID | / |
Family ID | 37717169 |
Filed Date | 2010-10-28 |
United States Patent
Application |
20100271233 |
Kind Code |
A1 |
Li; Qiming ; et al. |
October 28, 2010 |
SURFACE COMMUNICATION APPARATUS AND METHOD FOR USE WITH DRILL
STRING TELEMETRY
Abstract
An operation of drilling an earth borehole uses a drilling rig,
a drill string of drill pipes having its generally upper end
mechanically coupleable with and suspendable from the drilling rig,
a drive string portion of the drill string, mechanically coupleable
with the topmost drill pipe of said drill string, and a drive
mechanism mechanically coupleable with the drive string for
rotating the drive string and the drill string. A system for
generating electric power in the region of the drive string
includes an electric generator, which includes a rotating generator
component mounted on said drive string for rotation therewith and a
stationary generator component mounted on a stationary portion of
the drilling rig. The rotating generator component produces
electric power in the region of the drive string.
Inventors: |
Li; Qiming; (Sugar Land,
TX) ; Santoso; David; (Sugar Land, TX) ;
Sherman; Mark; (Houston, TX) ; Madhavan; Raghu;
(Houston, TX) ; LeBlanc; Randall P.; (Katy,
TX) ; Thomas; John A.; (Porter, TX) ; Montero;
Joseph; (Stafford, TX) |
Correspondence
Address: |
Conley Rose P.C
P.O.Box 3267
Houston
TX
77253
US
|
Assignee: |
Intelliserv, LLC
Houston
TX
|
Family ID: |
37717169 |
Appl. No.: |
12/787103 |
Filed: |
May 25, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11498847 |
Aug 3, 2006 |
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12787103 |
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60705326 |
Aug 4, 2005 |
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60708561 |
Aug 16, 2005 |
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Current U.S.
Class: |
340/854.9 |
Current CPC
Class: |
G01V 11/002 20130101;
E21B 17/003 20130101; E21B 17/028 20130101; E21B 47/13 20200501;
E21B 47/12 20130101 |
Class at
Publication: |
340/854.9 |
International
Class: |
G01V 3/00 20060101
G01V003/00 |
Claims
1. For use in an operation of drilling an earth borehole using: a
drilling rig, a drill string of drill pipes having its generally
upper end mechanically coupleable with and suspendable from the
drilling rig, a drive string portion of the drill string,
mechanically coupleable with the topmost drill pipe of said drill
string, and a drive mechanism mechanically coupleable with said
drive string for rotating the drive string and the drill string; a
system for generating electric power in the region of the drive
string, comprising: an electric generator that includes a rotating
generator component that is mounted on said drive string for
rotation therewith, and a stationary generator component that is
mounted on a stationary portion of the drilling rig, said rotating
generator component producing electric power in the region of said
drive string.
2. The system as defined by claim 1, wherein said stationary
generator component comprises a ring of magnets.
3. The system as defined by claim 2, wherein said rotating
generator component comprises at least one stator coil.
4. The system as defined by claim 3, wherein said rotating
generator component and stationary generator component are disposed
in close proximity such that magnetic flux from said ring of
magnets crosses said at least one stator coil.
5. The system as defined by claim 1, further comprising a
rechargeable battery charged by said electric generator, and
mounted on said drill string.
6. The system as defined by claim 1, further comprising a drill
telemetry subsystem forming at least a portion of a communication
link between downhole equipment on the drill string and an uphole
processor subsystem; and wherein said electric power from said
electric generator is adapted to provide power for said
communication link.
7. The system as defined by claim 4, further comprising a drill
telemetry subsystem forming at least a portion of a communication
link between downhole equipment on the drill string and an uphole
processor subsystem; and wherein said electric power from said
electric generator is adapted to provide power for said
communication link.
8. The system as defined by claim 1, further comprising: a system
for bidirectional communication between a downhole equipment and a
processor subsystem at the earth's surface, comprising a section of
wired drill pipes comprising at least the upper portion of the
string of drill pipes, and forming at least a portion of a
bidirectional communication link between the downhole equipment and
the top of the string of drill pipes; a first wireless transceiver
subsystem mounted on said drive string portion of the drill string,
for rotation in conjunction with the drill string, said first
wireless transceiver subsystem being coupled with said section of
wired drill pipe; and a second wireless transceiver subsystem
coupled with said uphole processor subsystem, said second wireless
transceiver subsystem communicating bidirectionally with said first
wireless transceiver subsystem; and wherein said electric power
from said electric generator is adapted for use by said first
transceiver subsystem.
9. For use in an operation of drilling an earth borehole using: a
drilling rig, a drill string of drill pipes having its generally
upper end mechanically coupleable with and suspendable from the
drilling rig, a drive string portion of the drill string,
mechanically coupleable with the topmost drill pipe of said drill
string, and a drive mechanism mechanically coupleable with said
drive string for rotating the drive string and the drill string; a
method for generating electric power in the region of the drive
string, comprising the steps of: providing a power generating unit
having a first component that is mounted on said drive string for
movement therewith; and producing power in the region of said drive
string from movement of said first component.
10. The method as defined by claim 9, wherein said step of
producing power comprises producing electric power from vibration
of said first component.
11. The method as defined by claim 9, further comprising mounting a
second component on a stationary portion of the drilling rig, and
wherein said step of producing power comprises producing power from
relative movement of said first component with respect to said
second component.
12. The method as defined by claim 11, wherein said relative
movement comprises rotation of said first component with respect to
said second component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application is a divisional of U.S. application
Ser. No. 11/498,847 filed Aug. 3, 2006, and claims priority from
U.S. Provisional Patent Application No. 60/705,326, filed Aug. 4,
2005, and also claims priority from U.S. Provisional Patent
Application No. 60/708,561, filed Aug. 16, 2005, and both said U.S.
Provisional Patent Applications are incorporated herein by
reference. The present Application contains subject matter that
relates to subject matter disclosed in copending U.S. patent
applications Ser. Nos. 11/498,845, titled "Bidirectional Drill
String Telemetry for Measuring and Drilling Control," (hereinafter
"the '845 Application") and 11/995,027, titled "Interface and
Method for Wellbore Telemetry System" (hereinafter "the '027
Application"), both filed on Aug. 3, 2006 of even date herewith,
and both assigned to the same assignee as the present
Application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] This invention relates to the fields of drilling and
producing hydrocarbon wells, and to the measuring of downhole
formation characteristics, and to drill string telemetry for
bidirectional communication of measurement and control information
between dowhhole and surface equipment, and to a surface
communication system for bidirectional communication between drill
string telemetry and a surface processor.
[0004] The advent of measurement while drilling (MWD) and logging
while drilling (LWD), as well as development of surface control of
special drilling processes, such as directional drilling, have been
important advances in the art of drilling and producing hydrocarbon
wells. These processes require communication, in both directions,
between the surface and the downhole measuring and drilling
equipment. At present, mud pulse telemetry is the only technique in
widespread commercial use for communication while drilling, between
downhole equipment and the surface. [Unless otherwise indicated,
references, throughout, to " while drilling," or the like, are
intended to mean that the drill string is in the borehole or
partially in the borehole as part of an overall drilling operation
including drilling, pausing, and or tripping, and not necessarily
that a drill bit is rotating.] In mud pulse telemetry, data is
transmitted as pressure pulses in the drilling fluid. However, mud
pulse telemetry has well known limitations, including relatively
slow communication, low data rates, and marginal reliability.
Current mud pulse technology is capable of sending MWD/LWD data at
only about 12 bits per second. In many cases, this rate is
insufficient to send all the data that is gathered by an LWD tool
string, or is limiting on the configuration of a desired tool
string. Also, mud pulse technology does not work well in extended
reach boreholes. Signaling from uphole to downhole, by regulating
mud pump flow, in order to control processes such as directional
drilling and tool functions, is also slow, and has a very low
information rate. Also, under certain circumstances, for example
underbalanced drilling employing gases or foamed drilling fluid,
current mud pulse telemetry cannot function.
[0005] There have been various attempts over the years to develop
alternatives to mud pulse telemetry that are faster, have higher
data rates, and do not require the presence of a particular type of
drilling fluid. For example, acoustic telemetry has been proposed,
which transmits acoustic waves through the drill string. Data rates
are estimated to be about an order of magnitude higher than mud
pulse telemetry, but still limiting, and noise is a problem.
Acoustic telemetry has not yet become commercially available.
Another example is electromagnetic telemetry through the earth.
This technique is considered to have limited range, depends on
characteristics, especially resistivity, of the formations
surrounding the borehole, and also has limited data rates.
[0006] The placement of wires in drill pipes for carrying signals
has long been proposed. Some early approaches to a wired drill
string are disclosed in: U.S. Pat. No. 4,126,848, U.S. Pat. No.
3,957,118 and U.S. Pat. No. 3,807,502, and the publication "Four
Different Systems Used for MWD," W. J. McDonald, The Oil and Gas
Journal, pages 115-124, Apr, 3, 1978.
[0007] The idea of using inductive couplers, such as at the pipe
joints, has also been proposed. The following disclose use of
inductive couplers in a drill string: U.S. Pat. No. 4,605,268,
Russian Federation published patent application 2140527, filed Dec.
18, 1997, Russian Federation published patent application 2040691,
filed Feb. 14, 1992, and WO Publication 90/14497A2, Also see: U.S.
Pat. No. 5,052,941, U.S. Pat. No. 4,806,928, U.S. Pat. No.
4,901,069, U.S. Pat. No. 5,531,592, U.S. Pat. No. 5,278,550, and
U.S. Pat. No. 5,971,072.
[0008] The U.S. Pat. No. 6,641,434 describes a wired drill pipe
joint that was a significant advance in the wired drill pipe art
for reliably transmitting measurement data in high-data rates,
bidirectionally, between a surface station and locations in the
borehole. The '434 Patent discloses a low-loss wired pipe joint in
which conductive layers reduce signal energy losses over the length
of the drill string by reducing resistive losses and flux losses at
each inductive coupler. The wired pipe joint is robust in that it
remains operational in the presence of gaps in the conductive
layer. The performance attendant these and other advances in the
drill string telemetry art provides opportunity for innovation
where prior shortcomings of range, speed, and data rate have
previously been limiting on system performance.
[0009] When a wired drill pipe system is used, it is necessary to
have a communication link between the topmost wired drill pipe and
a surface processor (which, inter alia, typically performs one or
more of the following functions: receiving and/or sending data,
logging information, and/or control information to and/or from
downhole and surface equipment, performing computations and
analyses, and communicating with operators and with remote
locations). Various approaches have been suggested, some of which
are summarized in U.S. Pat. No. 7,040,415, including use of a slip
ring device, and use of rotary electric couplings based on
induction or so-called transformer action. A slip ring (also known
as brush contact surfaces) is a well known electrical connector
designed to carry current or signals from a stationary wire into a
rotating device. Typically, it is comprised of a stationary
graphite or metal contact (a brush) carried in a non-rotating
component which rubs on the outside diameter of a rotating metal
ring (e.g., carried on the upper portion of a kelly joint). As the
metal ring turns, the electrical current or signal is conducted
through the stationary brush to the metal ring making the
connection.
[0010] Rotary electrical couplings based on induction (transformer
action), known, as rotary transformers, provide an alternative to
slip rings and contact brushes based upon conduction between
rotating and stationary circuitry, so no direct contact is
necessary. The transformer windings comprise a stationary coil and
a rotating coil, both concentric with the axis of rotation. Either
coil can serve as the primary winding with the other serving as the
secondary winding.
[0011] These types of approaches for surface communication have
certain limitations and drawbacks attendant the use of complex
electromechanical structures, and it is among the objects of the
present invention to provide a system for bidirectional
communication of signals between the topmost wired drill pipe and a
surface processor, with improved efficiency and reliability.
[0012] A further aspect of the drilling and measurement art that is
addressed herein relates to safety at the wellsite, and the problem
of powering a rotating assembly, at a location that may be
classified as a hazardous area, without the use of power carrying
wires. Existing techniques have certain limitations. For example,
mud turbines, which are powered by the moving drilling fluid, are
relatively complex and expensive to build and to maintain. The use
of ordinary batteries can be problematic when the drilling
operation must be interrupted for battery replacement. It is
accordingly among the further objects hereof to provide a safe,
efficient, and reliable source of electric power in conjunction
with the rotating drill string.
SUMMARY OF THE INVENTION
[0013] It has been recognized that wireless surface communication
could be used for communication between a drill string telemetry
system and a surface processor (see, for example, U.S. Pat. No.
7,040,415). However, the manner in which this can be advantageously
achieved has not heretofore been realized.
[0014] A form of the invention is directed for use in an operation
of drilling an earth borehole using: a drilling rig, a drill string
having its generally upper end mechanically coupleable with and
suspendable from the drilling rig, and downhole equipment on the
drill string. A system is provided for bidirectional communication
between the downhole equipment and a processor subsystem at the
earth's surface, comprising: a section of wired drill pipes
comprising at least the upper portion of the string of drill pipes,
and forming at least a portion of a bidirectional communication
link between the downhole equipment and the top of the string of
drill pipes; a drive string portion of the drill string,
mechanically coupleable with the topmost wired drill pipe; a drive
mechanism mechanically coupleable with said drive string portion,
for rotating the drill string; a first wireless transceiver
subsystem mounted on the drive string portion of the drill string,
for rotation in conjunction with the drill string; a cable,
electrically coupled between the top joint of the topmost wired
drill pipe and the first transceiver subsystem; and a second
wireless transceiver subsystem coupled with the uphole processor
subsystem, the second wireless transceiver subsystem communicating
bidirectionally with the first wireless transceiver subsystem. [As
used herein, the "drive string" portion of the drill string
comprises all subs, kelly, top drive, or the like that are
connected above the topmost drill pipe of the drill string. In
illustrated embodiments hereof; the topmost drill pipe is also the
topmost wired drill pipe of the drill string.]
[0015] Although, in some circumstances, a single wire could be
used, in a preferred embodiment of the invention, the cable
comprises a plurality of wires, such as a wire pair. In a form of
this embodiment, the section of wired drill pipe has inductive
couplers at the joints of each pipe, and the cable is electrically
coupled to the top joint of said topmost wired drill pipe by an
inductive coupling. Also, in a preferred embodiment of the
invention, the first transceiver subsystem includes a first antenna
subsystem, and the second transceiver subsystem includes a second
antenna subsystem. Each of the antenna subsystems can comprise a
plurality of antennas. The antennas can be at different azimuthal
positions with respect to the drive string.
[0016] In one embodiment of the invention, the drive string portion
of the drill string comprises a kelly, and in a form of this
embodiment, the drive string portion of the drill string further
comprises a saver sub between the kelly and the topmost wired drill
pipe. In another embodiment of the invention, the drive string
portion of the drill string comprises a top drive sub, and the
drive mechanism comprises a top drive that engages the top drive
sub. In a form of this embodiment, the drive string portion of the
drill string further comprises a saver sub between the top drive
sub and said topmost wired drill pipe.
[0017] In an embodiment of the invention, an antenna of the first
antenna subsystem and the first wireless transceiver subsystem are
mounted at substantially the same position on the drive string
portion of the drill string, and in another embodiment, an antenna
of the first antenna subsystem and at least part of said first
wireless transceiver subsystem are mounted at respectively
different positions on the drive string portion of the drill
string.
[0018] In accordance with a further form of the invention, an
electric generator is provided for generating electric power for
use by the first transceiver subsystem, the electric generator
including a rotating generator component that is mounted on the
drive string portion of the drill string and a stationary generator
component that is mounted on a stationary portion of the drilling
rig. In an embodiment of this form of the invention, the stationary
generator component comprises a ring of magnets, and the rotating
generator component comprises at least one stator coil. The
rotating generator component and stationary generator component are
disposed in close proximity such that magnetic flux from the ring
of magnets crosses the at least one stator coil.
[0019] Further features and advantages of the invention will become
more readily apparent from the following detailed description when
taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a diagram, partially in schematic form and
partially in block form, of a system in which embodiments of the
invention can be employed.
[0021] FIG. 2 is a diagram, partially in block form, of an existing
scheme for bidirectional wireless communication between a surface
communication sub and a surface computer.
[0022] FIG. 3 is a cross-sectional schematic diagram, partially in
block form, of a bidirectional surface communication subsystem in
accordance with an embodiment of the invention.
[0023] FIG. 4 is a cross-sectional schematic diagram, partially in
block form, of a bidirectional surface communication subsystem in
accordance with another embodiment of the invention.
[0024] FIG. 5 is a cross-sectional schematic diagram, partially in
block form, of a bidirectional surface communication subsystem in
accordance with a further embodiment of the invention.
[0025] FIG. 6 is a cross-sectional schematic diagram, partially in
block form, of a bidirectional surface communication subsystem in
accordance with another embodiment of the invention.
[0026] FIG. 7 is a diagram of an electric power generating
subsystem in accordance with an embodiment of the invention.
[0027] FIG. 8 is an exploded diagram of the FIG. 8 electric power
generating subsystem in accordance with an embodiment of the
invention.
[0028] FIG. 9 is a schematic diagram, partially in block form, of
the electric power generating subsystem of FIGS. 7 and 8, in
accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0029] FIG. 1 illustrates a wellsite system in which the present
invention can be employed. The wellsite can be onshore or offshore.
In this exemplary system, a borehole 11 is formed in subsurface
formations by rotary drilling in a manner that is well known. The
drilling could alternatively be mud-motor based directional
drilling, as is also well known.
[0030] A drill string 12 is suspended within the borehole 11 and
has a bottom hole assembly 100 which includes a drill bit 105 at
its lower end. The surface system includes platform and derrick
assembly 10 positioned over the borehole 11, the assembly 10
including a rotary table 16, kelly 17, hook 18 and rotary swivel
19. The drill string 12 is rotated by the rotary table 16,
energized by means not shown, which engages the kelly 17 at the
upper end of the drill string. The drill string 12 is suspended
from a hook 18, attached to a traveling block (also not shown),
through the kelly 17 and a rotary swivel 19 which permits rotation
of the drill string relative to the hook. As is well known, a top
drive system could alternatively be used.
[0031] In the example of this embodiment, the surface system
further includes drilling fluid or mud 26 stored in a pit 27 formed
at the well site. A pump 29 delivers the drilling fluid 26 to the
interior of the drill string 12 via a port in the swivel 19,
causing the drilling fluid to flow downwardly through the drill
string 12 as indicated by the directional arrow 8. The drilling
fluid exits the drill string 12 via ports in the drill bit 105, and
then circulates upwardly through the annulus region between the
outside of the drill string and the wall of the borehole, as
indicated by the directional arrows 9. In this well known manner,
the drilling fluid lubricates the drill bit 15 and carries
formation cuttings up to the surface as it is returned to the pit
27 for recirculation.
[0032] As is known in the art, sensors may be provided about the
wellsite to collect data, preferably in real time, concerning the
operation of the wellsite, as well as conditions at the wellsite.
For example, such surface sensors may be provided to measure
parameters such as standpipe pressure, hookload, depth, surface
torque, rotary rpm, among others.
[0033] The bottom hole assembly 100 of the illustrated embodiment
includes an interface sub 110, a logging-while-drilling (LWD)
module 120, a measuring-while-drilling (MWD) module 130, a
roto-steerable system and motor 150 for directional drilling, and
drill bit 105.
[0034] The LWD module 120 is housed in a special type of drill
collar, as is known in the art, and can contain one or a plurality
of known types of logging tools. (See also the above-referenced
copending U.S. patent application Ser. No. 11/498,845, filed of
even date herewith and assigned to the same assignee as the present
application.) The LWD module includes capabilities for measuring,
processing, and storing information, as well as for communicating
with the surface equipment. The LWD module can include, for
example, one or more of the following types of logging devices that
measure formation characteristics: a resistivity measuring device,
a directional resistivity measuring device, a sonic measuring
device, a nuclear measuring device, a nuclear magnetic resonance
measuring device, a pressure measuring device, a seismic measuring
device, an imaging device, and a formation sampling device.
[0035] The MWD module 130 is also housed in a special type of drill
collar, as is known in the art, and can contain one or more devices
for measuring characteristics of the drill string and drill bit.
The MWD tool can further include an apparatus (not shown) for
generating electrical power to the downhole system. This may
typically include a mud turbine generator powered by the flow of
the drilling fluid, although other power and/or battery systems may
be employed. The MWD module can include, for example, one or more
of the following types of measuring devices: a weight-on-bit
measuring device, a torque measuring device, a vibration measuring
device, a shock measuring device, a stick slip measuring device, a
direction measuring device, and an inclination measuring
device.
[0036] In the system of FIG. 1, a drill string telemetry system is
employed which, in the illustrated embodiment, comprises a system
of inductively coupled wired drill pipes 180 that extend from a
surface sub 185 to an interface sub 110 in the bottom hole
assembly. Depending on factors including the length of the drill
string, relay subs or repeaters can be provided at intervals in the
string of wired drill pipes, an example being represented at 182.
The relay subs, which can also be provided with sensors, are
further described in the '027 Application.
[0037] The interface sub 110 provides an interface between the
communications circuitry of the LWD and MWD modules and the drill
string telemetry system which, in this embodiment, comprises wired
drill pipes with inductive couplers. The interface sub 110, which
can also be provided with sensors, is described further in the '027
Application.
[0038] At the top of the wired drill string, a further interface
sub 185, can be provided, and serves, in this case, as a surface
sub. As described, for example, in the U.S. Pat. No. 7,040,415, the
wired drill pipes can be coupled with electronics subsystem that
rotates with kelly 17 and include a transceiver and antenna that
communicate bidirectionally with antenna and transceiver of logging
and control unit 4 which, in the present embodiment, embodies the
uphole processor subsystem. In an embodiment hereof, the interface
sub 185 can comprise a wired saver sub (to be described), and the
electronics of a transceiver 30 is mounted on the kelly, or other
part of the drive string, as will be described. In FIG. 1, a
communication link 175 is schematically depicted between the
electronics subsystem 30 and antenna of the logging and control
unit 4. Accordingly, the configuration of FIG. 1 provides a
communication link from the logging and control unit 4 through
communication link 175, to surface sub 185, through the wired drill
pipe telemetry system, to downhole interface 110 and the components
of the bottom hole assembly and, also, the reverse thereof, for
bidirectional operation.
[0039] As described in the '027 Application while only one logging
and control unit 4 at one wellsite is shown, one or more surface
units across one or more wellsites may be provided. The surface
units may be linked to one or more surface interfaces using a wired
or wireless connection via one or more communication lines. The
communication topology between the surface interface and the
surface system can be point-to-point, point-to-multipoint or
multipoint-to-point. The wired connection includes the use of any
type of cables (wires using any type of protocols (serial,
Ethernet, etc.) and optical fibers. The wireless technology can be
any kind of standard wireless communication technology, such as
IEEE 802.11 specification, Bluetooth, zigbee or any non-standard RF
or optical communication technology using any kind of modulation
scheme, such as FM, AM, PM, FSK, QAM, DMT, OFDM, etc. in
combination with any kind of data multiplexing technologies such as
TDMA, FDMA, CDMA, etc.
[0040] FIG. 2 shows a block diagram of a type of wireless
transceiver subsystem electronics that can be used for the
electronics 30 of FIG. 1. Reference can also be made to U.S. Pat.
No. 7,040,415. A signal from/to the inductive coupler of the top
joint of topmost wired drill pipe is coupled with a WDP modem. The
WDP modem 221 is, in turn, coupled with wireless modem 231. A
battery 250 and power supply 255 are also provided to power the
modems. Other power generating means, which may be more preferred,
are described hereinbelow. The logging and control unit also has,
for example, a transceiver with a wireless modem.
[0041] The WDP surface modem is adapted to communicate with one or
more modems, repeaters, or other interfaces in the downhole tool
via the wired drill pipe telemetry system. Preferably, the modems
provide two way communications. The modem communicates with another
modem or repeater or other sub located in the downhole tool. Any
kind of digital and analog modulation scheme may be used, such as
biphase, frequency shift keying (FSK), quadrature phase
shift-keying (QPSK), Quadrature Amplitude Modulation (QAM),
discrete multi tone (DMT), etc. These schemes may be used in
combination with any kind of data multiplexing technologies such as
Time Division Multiplexing (TDM), Frequency Division Multiplexing
(FDM), etc. The modem may include functionality for drill pipe
diagnostics and downhole tool diagnostics.
[0042] Although a single surface processor is depicted, it will be
understood that plural surface processors, in the form of
logging/control units or other forms, can be provided at diverse
locations, with wired and/or wireless transceiver connection, it
being further understood that any of the modes of communication
mentioned herein can be utilized, and that compression and/or
encryption of data can also be utilized. Each unit can have its own
antenna(s) and/or shared antennas. The antennas can be provided at
optimum locations and with optimum orientations to maximize signal
strength and quality. Communication to/from remote locations,
including communication via satellite, can also be implemented.
[0043] FIG. 3 shows an embodiment of the invention in which a
special saver sub 340 is provided between the kelly 350 and the
topmost wired drill pipe 181. The saver sub 340 has an inductive
coupler 341 at its lower end that electrically couples with the
inductive coupler 189 of the topmost wired drill pipe. A cable 315,
which is connected to inductive coupler 341, exits saver sub 340
through a sealed port, and runs externally of kelly 350 to the
transceiver subsystem 330, which includes antenna(s) 335. At the
exit position of the cable on the saver sub 340, a connector 346
can be provided. The cable running along the outside of kelly 350
can be sealed in a groove in the kelly and, for example, be
protected by an epoxy or peek materials. A further connector can be
provided at the transceiver subsystem electronics. The cable 315 is
provided with at least a wire pair.
[0044] In the embodiment of FIG. 4, the saver sub 440 and kelly 450
have internal electrical cabling, and the drive string includes a
special top sub 470, above kelly 450, on which the wireless
transceiver subsystem 430 is mounted. In a form of this embodiment,
the saver sub 440 and the kelly 450 each have inductive couplers at
both ends, with a cable (again, and throughout, preferably
including at least a wire pair), designated 441 and 451,
respectively, running between the ends of each. It will be
understood that other types of coupling at the joints could
alternatively be used, here, and in other embodiments. The special
top sub 470, which is mounted above kelly 450, rotates with the
drill string. In this example, the top sub 470 has an inductive
coupler at its lower end, and an internal cable 471 that couples
with the wireless transceiver subsystem 430.
[0045] In the examples of the embodiments of FIGS. 3 and 4, the
wireless transceiver subsystem electronics, as well as the
associated antenna(s), are in one general location on the drive
string portion of the drill string, but, it will be understood that
parts or all of the electronics, with contiguous or separated
antenna(s), can be at a plurality of locations. For example, in the
embodiment of FIG. 5, a special surface sub 590 is employed between
saver sub 440 and kelly 550. In this example, the saver sub 440 has
inductive couplers at both ends and internal wiring (as in FIG. 4),
and the special surface sub 590 has an inductive coupler at its
lower end, with internal wiring, represented at 591, running to the
electronics 530. In this example, the wireless transceiver
subsystem electronics 530, or at least a portion thereof, are
mounted internally in the special surface sub 590. An example of
internal packaging of electronics in a sub is shown in the '027
Application filed of even date herewith, and assigned to the same
assignee as the present application. In the present embodiment, the
antenna(s) 535 (and, if desired, a portion of the associated
electronics) are mounted on the kelly 550 and coupled with the rest
of the electronics 530 via cable 531 which, in this embodiment,
exits the special sub 590 at a sealed port or connector, and can be
carried in a groove in the kelly in the same manner as was
described above. If desired, the bidirectional link between
electronics 530 and antenna(s)/electronics 535 can carry a
digitized signal. In this embodiment, it will be understood that
the sub 590 and a portion of kelly 550 may be under the level of
the mud at least some of the time, but the antenna(s)/electronics
535 will be above the mud level. FIG. 5 shows plural antennas that
rotate with the kelly, as it will be understood that azimuthally
redundant antennas on the rotating drive string will minimize dead
spots or weak spots of the wireless link. The same is applicable to
the other embodiments. Also, plural antennas of the wireless
transceiver subsystem can be advantageous.
[0046] FIG. 6 shows an embodiment of the invention for use in
conjunction with a top drive 605. In the FIG. 6 example, a saver
sub 440, coupled with the topmost wired drill pipe 181, has
inductive couplers at both ends, connected by cable 441, as in the
embodiments of FIGS. 4 and 5. A top drive sub 690 is provided
between the top drive 605 and saver sub 440, and the wireless
transceiver subsystem 630 of this embodiment is mounted on the top
drive sub 690. Also in this embodiment, the top drive sub has an
inductive coupler at its lower end, and internal cable 691 that
runs from the inductive coupler to the subsystem 630. However, it
will be understood that an external cable could be used, as in the
FIG. 3 embodiment, or that the electronics and/or antenna(s) could
be split, as in the FIG. 5 embodiment.
[0047] FIGS. 7-9 show an embodiment of a form of the invention
wherein a safe and reliable source of power is provided on
rotational components at the well site, which can be used, for
example, to power the wireless transceiver subsystem 30 and/or for
other applications. In this embodiment, a magnet ring 710 operates
as a stationary generator component and is mounted on a stationary
portion of the drilling rig represented at 705, for example a
mounting adjacent a kelly or a top drive. A surface sub 720 (which
may, for example, be one of the surface subs of FIGS. 3-6) includes
a stator 725 (FIGS. 8 and 9), rectifier 726, charging circuit 727,
and rechargeable batteries 728 (FIG. 9), which are used, inter
alia, for powering the first transceiver subsystem 30. The stator
725 has one or more stator coils, is annularly aligned with the
magnet ring, and is in close proximity therewith so that flux from
the magnet ring crosses the one or more stator coils of the stator
725 as the stator 725 rotates with the drive string portion of the
drill string. The magnet ring, in this embodiment, comprises
magnets arranged with alternating polarities. The alternating
current from the stator is rectified by rectifier 726, the output
of which is direct current that is input to charging circuit 727,
the output of which, in turn, charges rechargeable batteries 728.
In an embodiment hereof, the batteries power the first wireless
transceiver subsystem 30, and can also power other circuits, such
as for measurement and/or communication. Also, it will be
understood that the output of the generator and/or rectifier could,
if desired, be used for directly powering circuits or subsystems of
the equipment.
[0048] The invention has been described with regard to a number of
particular preferred embodiments, but variation within the spirit
and scope of the invention will occur to those skilled in the art.
For example, although FIGS. 3-6 show various combinations of
couplers, internal and external cabling, internal and/or external
mounting of portions of the electronics, use of a saver sub(s)
and/or special surface sub(s), etc., it will be understood that
other combinations are possible and are contemplated within the
scope defined by the claims. Also, while a wired drill pipe
subsystem is one preferred embodiment of a drill string telemetry
subsystem, it will be recognized that other forms of drill string
telemetry, an example being acoustic drill string telemetry, can be
used, in which case a transducer subsystem can be provided at the
top of drill string telemetry subsystem to convert to/from
electrical signals. Also, it will be understood that other
techniques which make use of motion of the drill string, including
rotational or vibrational motion, can be used to generate power in
the region of the drill string.
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