Downhole to surface communications platform for drilling applications

Patent metadata

Field	Value
Publication number	US-12378876-B2
Application number	US-202318387160-A
Country	US
Kind code	B2
Filing date	Nov 6, 2023
Priority date	Nov 3, 2020
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

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 for downhole to surface communications, 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;
a communications link disposed at a surface adjoining above ground in the data communication with the drilling assembly through the slip ring assembly;
the end pipe portion coupled to a final pipe segment of the drilling assembly, the end pipe portion comprising an electronics assembly, the electronics assembly comprising at least one electronic component for transferring data to the slip ring assembly via the drilling assembly; and
a drill bit operably coupled with the end pipe portion for drilling a borehole;
each pipe segment of the plurality of pipe segments comprising an outer conductor portion, 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 the hollow inner conductor portion from electrical contact with the outer conductor portion;
wherein the hollow inner conductor portion forming a tube that defines a fluid communication pathway through the drilling assembly; and
wherein the outer conductor portion and the hollow inner conductor portion are not in the electrical contact.

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 to said each pipe segment of the plurality of pipe segments;
a first dielectric portion and a waveguide;
the waveguide in the 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 drilling assembly with drill 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 a plurality of electronic components for generating the data to the communications link; the plurality of electronic components selected from a navigation sensor, a force sensor, a torque sensor, accelerometers, and surface equipment used to process the data.

6. The drilling assembly of claim 5 , wherein radio frequency communications are configured up 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 in the 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 a first end having a male coupler portion, and a second end opposite the first end, the second end comprising a female coupler portion, wherein adjacent pipe segments of the plurality of pipe segments being connected continuously 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 hollow inner conductor portion of said each pipe segment or respective connected drill segments.

10. The drilling assembly of claim 1 , further comprising a compliant contact arrangement disposed between adjacent pipe segments of the plurality of 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 second contact portion; the first contact portion comprising a first center contact and a first insulator connected with a second center contact and a second insulator of an adjacent contact portion when coupled.

11. The drilling assembly of claim 10 , further comprising a spherical interface having a ball and a first spring at a first end and a socket and a second spring at a second end, wherein the ball and the socket are positively engaged between respective adjoining inner conductor portions.

12. A pipe segment for a drilling assembly comprising:
an outer conductor portion, 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 forming a tube that defines a sealed fluid passage through the drilling assembly therethrough when a plurality of pipe segments are continuously fluidly connected;
wherein the outer conductor portion and the hollow inner conductor portion are not in the electrical contact; and wherein the pipe segment further comprising:
a first end having a male coupler portion, and
a second end opposite the first end;
the second end comprising a female coupler portion co-operable with an adjacent pipe segment for connecting continuously in the drilling assembly with the sealed fluid passage and data communication.

13. The pipe segment of claim 12 , 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 the male interface portion to align the hollow inner conductor portion to connect the pipe segment in the sealed fluid passage and the data communication with the adjacent pipe segment.

14. The pipe segment of claim 12 , further comprising:
a compliant contact arrangement;
the compliant contact arrangement configured to seal a fluid path and conduct electrical signals between adjacent pipe segments;
wherein a contact portion of the compliant contact arrangement being mateable with an adjoining contact portion;
the contact portion comprising a first center contact and a first insulator cooperative with a second center contact and a second insulator of the adjoining contact portion when coupled.

15. The pipe segment of claim 14 , further comprising:
a spherical interface having a ball and a first spring at the first end and a socket and a second spring at the second end, wherein the ball and the socket are positively engaged by the first and second springs disposed between adjoining inner conductor portions.

16. An electronics assembly for a downhole to surface communications system for a drilling assembly, the electronics assembly comprising:
a first end configured for connection to a pipe segment of the drilling assembly, and a second end configured for connection to a drill bit, the pipe segment having a hollow inner conductor portion and an outer conductor portion, the first end configured to

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

• E21B17/0285

  characterised by electrically insulating elements · CPC title

• E21B47/13 Primary

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

• E21B17/028 Primary

  Electrical or electro-magnetic connections · CPC title