Downhole MCEI inductive coupler with helical coil
11603712 · 2023-03-14
Inventors
Cpc classification
E21B17/0283
FIXED CONSTRUCTIONS
E21B17/003
FIXED CONSTRUCTIONS
International classification
E21B17/20
FIXED CONSTRUCTIONS
Abstract
A downhole data transmission system comprising a composite polymeric annular block including a ferrite channel molded therein. The block being suitable for being housed within an annular groove or trough in the shoulder of a drill pipe. The annular block comprising a volume of sub-micron and micron elements of Fe and Mn. The ferrite channel defining an annular core region and an insulated helical coil laying within the core region. One end of the insulated helical coil passing through the ferrite channel and the annular block. A gasket molded into the block and extending from the block provides a sealed pathway for the end of the coil to exit the groove and connect to a cable; the other end of the coil being connected to ground. The annular block further includes a bumper protruding from its peripheral wall and a void opening within the annular block proximate the bumper.
Claims
1. A data transmission system, comprising a composite annular polymeric block suitable for housing in an annular groove in a shoulder of a drill pipe; the composite annular polymeric block comprising an annular magnetically conductive electrically insulating ferrite channel molded therein; a helical electrical conductor comprising a plurality of vertical loops electrically grounded to the shoulder is disposed within the ferrite channel, and wherein the helical electrical conductor is connected to a cable running the length of the drill pipe and connected to a similarly configured helical electrical conductor at the opposite end of the drill pipe.
2. The data transmission system of claim 1, wherein the ferrite channel comprises a core region.
3. The data transmission system of claim 2, wherein the plurality of vertical loops average between 2 and 60 loops per inch within the core region of the ferrite channel.
4. The data transmission system of claim 2, wherein the vertical loops are encased within an electrically insulating compound within the core region of the ferrite channel.
5. The data transmission system of claim 2, wherein a major diameter of the vertical loops is less than a major diameter of the core region of the ferrite channel.
6. The data transmission system of claim 2, wherein a major diameter of the vertical loops is between ten percent and ninety percent of a major diameter of the core region of the ferrite channel.
7. The data transmission system of claim 2, wherein the core region of the ferrite channel is open.
8. The data transmission system of claim 1, wherein the ferrite channel comprises a circular core region.
9. The data transmission system of claim 1, wherein the ferrite channel comprises a non-circular core region.
10. The data transmission system of claim 1, wherein the composite polymeric block comprises a polymer selected from the group consisting of epoxy, synthetic rubber, polyurethane, silicon, a fluorinated polymer, polytetrafluoroethylene, perfluoroalkoxy, or a combination thereof.
11. The data transmission system of claim 1, wherein the composite polymeric block comprises a volume of particles comprising micron and submicron elements of Fe and Mn of between three percent and sixty-seven percent of the volume of polymer.
12. The data transmission system of claim 1, wherein the composite polymeric block comprises a protruding bumper.
13. The data transmission system of claim 12 wherein a void opening within the polymeric block is located proximate the protruding bumper.
14. The data transmission system of claim 1, wherein the annular groove comprises a bumper seat.
15. The data transmission system of claim 1, wherein the composite polymeric block comprises one or more void openings within the composite polymeric block.
16. The data transmission system of claim 1, wherein the helical electrical conductor comprises an electrically insulated conductive wire.
17. The data transmission system of claim 1, wherein the composite polymeric block comprises a gasket molded therein.
18. The data transmission system of claim 17, wherein the gasket protrudes from the composite polymeric block.
19. The data transmission system of claim 17, wherein the gasket is suitable for sealing disposition within a gasket seat in the annular groove of the drill pipe shoulder.
20. The data transmission system of claim 17, wherein the gasket comprises a sealed pathway for the helical electrical conductor to exit the polymeric block and the annular groove.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3) (Prior Art)
(4) (Prior Art)
(5) (Prior Art)
(6) (Prior Art)
(7) (Prior Art)
(8) (Prior Art)
(9) (Prior Art)
(10) (Prior Art)
(11) (Prior Art)
(12) (Prior Art)
(13) (Prior Art)
(14) (Prior Art)
(15) (Prior Art)
(16) (Prior Art)
(17) (Prior Art)
(18) (Prior Art)
(19) (Prior Art)
(20) (Prior Art)
(21) (Prior Art)
(22) (Prior Art)
(23) (Prior Art)
(24) (Prior Art)
(25) (Prior Art)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(26) Referring to
(27) The ferrite channel or trough 220 may comprise a core region 225, partially defined by the inside wall 250 of the ferrite channel 220. The ferrite channel 220 may be open on its top side 215. The core region 225 may be circular or non-circular in shape. The vertical loops 285 of the helical conductor 230 may be constrained within the core region 225. The major diameter of the vertical loops 285 may be less than the major diameter of the core region 225. The diameter of the vertical loops 285 may be equal to between ten percent and ninety percent of the diameter of the core region 225. The open portion 215 of the ferrite channel or trough 220 may be filled with a composite material. The composite material may comprise a material similar to the polymeric block 210. The top surface of the ferrite channel 220 defining the open portion 215 of the core region 225 may be exposed along the top surface 215 of the annular polymeric block 210. The plurality of vertical loops 285 may average between 2 and 60 loops 285 per linear inch of the annular ferrite channel 220 within the core region 225 of the ferrite channel 220. The annular ferrite channel 220 may house a quantity of vertical loops 285 depending on the circumference of the annular ferrite channel 220. The vertical loops 285 may comprise an insulating coating or sheath. The core region 225 may be filled with a non-electrically conducting material or the core region 225 may be devoid of a filler.
(28) The composite polymeric block 210 may comprise a polymer selected from the group consisting of epoxy, synthetic rubber, polyurethane, silicon, a fluorinated polymer, polytetrafluoroethylene, perfluoroalkoxy, or a combination thereof. The composite polymeric block 210 may comprise a volume of particles comprising micron and submicron elements of Fe and Mn of diameters averaging between 150 nm and 2500 nm. The volume of particles may average between three percent and sixty-seven percent of the volume of the polymer.
(29) The composite polymeric block 210 may comprise one or more protruding bumpers 270 along its longest peripheral side. Or the protruding bumper 270 may circumscribe the longest periphery of the polymeric block 210. The bumper 270 may comprise a dimple on its anterior surface. The protruding bumper 270 may be aligned with a bumper seat 255 disposed in an adjacent wall of the annular groove 265 in the drill pipe shoulder 205.
(30) The composite polymeric block 210 may comprise one or more void openings 260 within the composite polymeric block 210. A void opening 260 within the polymeric block 210 may be located proximate the protruding bumper 270. The presence of the void opening 260 proximate the protruding bumper 270 may provide resiliency in the polymeric block 210 as the block is installed into the annular groove 265.
(31) The composite polymeric block 210 may comprise a gasket 235. The gasket 235 may be molded into the polymeric block 210 or the gasket may be installed into the block 210 subsequent to the block's 210 formation. The gasket 235 may comprise an axial opening. The gasket 235 may protrude from the composite polymeric block 210. The axial opening may provide a pathway for the helical wire 245 to exit the polymeric block 210 on its way to connect with the cable 275. The gasket 235 may be disposed within a gasket seat 240 in the drill pipe shoulder 205 adjacent the polymeric block 210. The gasket seat 240 may allow the gasket 235 to produce a pressure and fluidic seal between the shoulder 205 and the polymeric block 210. The gasket 235 may further provide a pressure and fluidic seal between the exiting wire 245 and the block 210. In addition to providing a seal for the block 210, the gasket may be used to orient the polymeric block 210 within the annular groove 265. A similar gasket 235 may be used to seal the other end of the helical conductor 280 that leads to ground.
(32) The following detailed description is taken from the '177 reference. The following description relates equally to
(33) Referring to (Prior Art)
(34) The downhole tool string 31 is made up of components, as shown in (Prior Art)
(35) As shown, the MCEI circular trough 46 houses an electrically conductive coil 45. Preferably the MCEI trough is made from a single MCEI material, such as ferrite. The MCEI material may also be soft iron, nickel iron alloys, silicon iron alloys, cobalt iron alloys or mu-metals.
(36) Alternatively, the MCEI trough may be of a combination of materials, such as a magnetizable element comprising a multi-laminar body. The element may comprise a plurality of ductile, generally U-shaped leaves that are electrically conductive. The leaves are less than about 0.0625″ thick and are separated by an electrically insulating material. These leaves are aligned so as to form a generally circular trough. The permeable and ductile material may be associated with the class of soft magnetic materials.
(37) The coil 45 may comprises at least two fractional loops 67, 70 of insulated wire. Preferably, the wire is made of copper and is insulated with a varnish, an enamel, or a polymer. When the components of the downhole tool string 31 are made up, the transmission elements 38, 47 line up adjacent to each other and allow data transmission between components 36, 57. A threaded portion 48 located between the primary shoulder 49 and secondary shoulder 39 of the pin end 40 and a threaded portion 50 located between the primary shoulder 51 and secondary shoulder 41 of the box end 42 provide a means of attachment for the downhole components 36, 57.
(38) (Prior Art)
(39) Preferably, the fractional loops may be equal in length, for example: two half loops, three third loops, and four quarter loops. In the preferred embodiment, the coil comprises two half loops. Alternatively, the fractional loops may be different lengths, for example: one half loop combined with two quarter loops, and one third loop combined with one three quarter loop.
(40) In the preferred embodiment, a connecting cable 66 times the arrival of the electrical signals to the fractional loops of the coil 45. In the preferred embodiment a first fractional loop 67 extends halfway around the channel 55 where it makes a first contact 69 with the connecting cable 66 which leads to ground. The connecting cable 66 makes a second contact 68 with the first fractional loop 67 where the lead wire 52 enters the annular housing 43. The second contact 68 creates a second signal, which is passed along the connecting cable 66. The second signal arrives at a second fractional loop 70 approximately at the same time as the first signal arrives at the first contact 69. It believed that approximately as the first signal leaves the channel 55, the second signal enters the channel 55 and the coil 45 experiences a continuous circuit. The second fractional loop 70 is preferably grounded to the annular housing 43 in the void 54 in the MCEI trough. In the preferred embodiment, the grounded portion 56 of the coil 45 is brazed to the annular housing 43. In some embodiments of the present invention the coil 45 and MCEI circular trough 46 are disposed in a groove formed by the secondary shoulders 39, 41 of both the pin end 40 and also of the box end 42 of the downhole component 36.
(41) As the signal travels along the fractional loops 67, 70 of the coil 45, the magnetic field from the electrical current is magnified by the MCEI trough. The magnified magnetic field influences the MCEI trough in the adjacent transmission element 47 in the adjacent downhole component 57. Preferably, the electrically conducting coils are arranged in a manner to allow the magnetic fields to generate a magnetic transmission circuit. A magnetic transmission circuit may be allowed by disposing one coil in a clockwise direction in the MCEI circular trough 46 and disposing an adjacent coil in a counterclockwise direction in an adjacent segmented circular trough 46 of MCEI trough. The coil in the adjacent transmission element 47 is influenced by the magnetic transmission circuit to generate an electrical current and that signal is passed to the electrical conductor 58 in the adjacent downhole component 57. It is believed that the fractional loops 67, 70 reduce the inductance of the electrically conducting coil 45. It is further believed that the reduced inductance reduces impedance reflections; therefore, the reduced inductance reduces signal loss and attenuation.
(42) In the preferred embodiment, a passage 59 is formed in the component 36 for the electrical conductor 44 and lead wire 52. Preferably the passage 59 runs from the secondary shoulder 39 to an opening 60 in the inner diameter 61 of the downhole component 36. The passage 59 may be a drilled hole. (Prior Art)
(43) (Prior Art)
(44) The connecting cable 66 may a pair of twisted wires 71, 72. The connecting cable 66 may alternatively be a shielded pair 79 of twisted wires 71, 72. In another aspect of the present invention, the connecting cable 66 is a coaxial cable 74. Alternatively, the connecting cable 66 is a triaxial cable 80. In another aspect of the present invention, the connecting cable 66 is shielded twin axial cable 81. (Prior Art)
(45) In (Prior Art)
(46) An embodiment of a coil 45 with four fractional loops 82, 83, 84, 85 of equal length is shown in (Prior Art)
(47) (Prior Art)
(48) (Prior Art)
(49) (Prior Art)
(50) (Prior Art)
(51) In another aspect of the invention, a bend 99 is made in the annular housing 43 to provide a place for the connecting cable 66; an embodiment is shown in (Prior Art)
(52) (Prior Art)
(53) The description above and the attached figures are meant to illustrate specific embodiments of the present invention and not limit its scope. Those having ordinary skill in the art will appreciate that other embodiments will fall within the scope and spirit of the invention as defined in the appended claims.