Downhole to surface communications platform for drilling applications

Patent metadata

Field	Value
Publication number	US-11808144-B1
Application number	US-202017087987-A
Country	US
Kind code	B1
Filing date	Nov 3, 2020
Priority date	Nov 3, 2020
Publication date	Nov 7, 2023
Grant date	Nov 7, 2023

Abstract

A drilling assembly for downhole to surface communications is provided. The drilling assembly includes a series of pipe segments coupled in fluid communication between a slip ring assembly and an end pipe portion. The slip ring assembly is coupled in data and fluid communication with the pipe segments. A surface communications link is in data communication with the drilling assembly via the slip ring assembly. An end pipe portion is coupled with the drilling assembly that includes an electronics assembly with electronic components for transferring data to the slip ring assembly via the drilling assembly. A drill bit is operably coupled with the end pipe portion for drilling a borehole. Each pipe segment includes an outer conductor portion, a hollow inner conductor portion, and a dielectric portion for electrical isolation between the outer conductor portion and the inner conductor portion.

First claim

The invention claimed is:

1. A drilling assembly, comprising:
a plurality of pipe segments coupled in serial fluid communication, a slip ring assembly, and an end pipe portion;
the slip ring assembly coupled in data communication and in the serial fluid communication with the plurality of pipe segments and a communications link;
the communications link disposed at a surface above the drilling assembly and in the data communication with the slip ring assembly;
the end pipe portion coupled to the plurality of pipe segments, the end pipe portion comprising an electronics assembly, the electronics assembly comprising one or more electronic components for transferring data between the end pipe portion and the slip ring assembly via the plurality of pipe segments; and
a drill bit operably coupled with the end pipe portion for drilling a borehole;
wherein each pipe segment of the plurality of pipe segments comprises an outer conductor portion that forms an outer surface of said each pipe segment, a hollow inner conductor portion, and a dielectric portion disposed between said outer conductor portion and said hollow inner conductor portion;
the dielectric portion insulating said hollow inner conductor portion from electrical contact with the outer conductor portion;
the hollow inner conductor portion defining a fluid communication pathway through the drilling assembly; and
wherein the data is transferred between the end pipe portion and the slip ring assembly via the plurality of pipe segments by way of the hollow inner conductor portion;
a compliant contact arrangement disposed between adjacent pipe segments of the drilling assembly, the compliant contact arrangement configured to seal a fluid path and conduct electrical signals between the adjacent pipe segments;
wherein a first contact portion mateable with an adjoining inner conductor portion of a second contact portion;
the first contact portion comprising a first center contact and a first insulator cooperative with a second center contact and a second insulator of the second contact portion when coupled; and
a spherical interface having a ball and a first spring at a first end of said each pipe segment and a socket and a second spring at a second end of said each pipe segment, wherein the ball and the socket are positively engaged between respective adjoining hollow inner conductor portions.

2. The drilling assembly of claim 1 , wherein the slip ring assembly comprises:
a stationary sleeve portion supporting a rotatable internal mandrel;
the internal mandrel connected with the to a said each pipe segment of the plurality of pipe segments;
a first dielectric portion and a waveguide;
the waveguide in a first data communication with a data port disposed on the sleeve portion;
the data port comprising one or more conductors to transmit and receive electronic communication signals between the communications link and the electronics assembly; and
the internal mandrel coupled to the plurality of pipe segments to generate torque to the drill bit.

3. The drilling assembly of claim 1 , wherein the outer conductor portion comprises a conductive material.

4. The drilling assembly of claim 1 , wherein the electronics assembly comprises a data link between the electronics assembly, the electronics assembly further comprising a radio frequency transceiver, a specialty drill pipe, and a radio frequency receiving means for extracting a data signal.

5. The drilling assembly of claim 4 , wherein the electronics assembly further comprises the one or more electronic components for generating a second data to a the communications link; the one or more electronic components selected from a navigation sensor, a force sensor, a torque sensor, an accelerometers, and surface equipment used to process the second data.

6. The drilling assembly of claim 5 , wherein radio frequency communications are configured to 500 meters (m) with a range of attenuation between 10 dB to 20 dB.

7. The drilling assembly of claim 6 , wherein the plurality of pipe segments extend up to 5 kilometers, and transmit frequencies are in a range of 100 kHz/kBit to 500 kHz/kBit with attenuation between 13 dB to 32 dB.

8. The drilling assembly of claim 1 , wherein said each pipe segment comprises the first end having a male coupler portion, and the second end opposite the first end, the second end comprising a female coupler portion, wherein the adjacent pipe segments being continuously connected in the drilling assembly for the serial fluid communication and the data communication.

9. The drilling assembly of claim 8 ,
wherein a female interface portion is configured at the first end and a male interface portion is configured at the second end;
the female interface portion having a first tapered end co-operable with a second tapered end of the male interface portion to align the respective adjoining hollow inner conductor portions or respective connected drill segments.

10. A pipe segment for a drilling assembly comprising:
an outer conductor portion forming an outer surface of the pipe segment, a hollow inner conductor portion defining a fluid flow passage therethrough, and a dielectric portion disposed between said outer conductor portion and said hollow inner conductor portion;
the dielectric portion insulating the hollow inner conductor portion from electrical contact with the outer conductor portion;
the hollow inner conductor portion defining the fluid flow passage to be sealed therethrough;
wherein the pipe segment is capable of mating to a mirror image pipe segment to continuously form a the fluid flow passage therethrough the pipe segment and the mirror image pipe segment;
a compliant contact arrangement disposed between the pipe segment and the mirror image pipe segment of the drilling assembly;
the compliant contact arrangement configured to seal the fluid flow passage and conduct electrical signals between the pipe segment and the mirror image pipe segment; wherein a first contact portion of the pipe segment being mateable with an adjoining inner conductor portion of a second contact portion of the mirror image pipe segment; the first contact portion comprising a first center contact and a first insulator cooperative with a second center contact and a second insulator of the second contact portion when coupled, wherein data is transferred between the pipe segment and the mirror image pipe segment; and
a spherical interface having a ball and a first spring at a first end of the pipe segment and a socket and a second spring at a second end of the pipe segment, wherein the ball and the socket are positively engaged by the first and second springs disposed between respective adjoining inner conductor portions.

11. The pipe segment of claim 10 , further comprising:
the first end having a male coupler portion, and the second end opposite the first end;
the second end comprising a female coupler portion co-operable with an adjacent pipe segment for continuously connecting a the drilling assembly with the sealed fluid flow passage and data communication.

12. The pipe segment of claim 10 , further comprising:
a female interface portion disposed at the first end and a male interface portion disposed at the second end;
the female interface portion having a first tapered end co-operable with a second tapered end of a second male interface portion of an adjacent pipe segment to align the hollow inner conductor portion of the pipe segment to an adjacent hollow inner conductor portion of the adjacent pipe segment to connect the pipe segment to the adjacent pipe segment in the sealed fluid flow passage and data communication with the adjacent pipe segme

Assignees

• Nat Tech & Eng Solutions Sandia Llc

Inventors

• Su Jiann-Cherng
• Krein Jason P
• Borchardt John Joseph
• Robey Richard Ellis
• Wright Andrew Alexander
• Pope Joseph Samuel
• Myers Taylor Anthony
• Grubelich Mark C
• Blankenship Douglas A

Classifications

• E21B47/13 Primary

  by electromagnetic energy, e.g. radio frequency · CPC title

• E21B17/0285

  characterised by electrically insulating elements · CPC title

• E21B17/028 Primary

  Electrical or electro-magnetic connections · CPC title