Patent Application
20140332235
During subterranean drilling and completion operations, various power and/or communication signals may be transmitted through pipe segments or other downhole components, e.g., via a “wired pipe” configuration. Such configurations include electrical, optical or other conductors extending along the length of selected pipe segments. The conductors are operably connected between pipe segments by a variety of coupling configurations.
One such coupling configuration includes a threaded male-female configuration often referred to as a pin box connection. The pin box connection includes a male member, i.e., a “pin” that includes an exterior threaded portion, and a female member, i.e., a “box”, that includes an interior threaded portion and is configured to receive the pin in a threaded connection.
Signal repeaters have been used to enhance transmission of power and communications between components over a telemetry line or system. Such repeaters are provided to reduce signal loss during transmission of data from downhole components to the surface.
An apparatus for retaining electronic components in a downhole component coupling mechanism includes: a power supply frame including a first housing configured to retain a power supply therein and isolate the power supply from downhole fluids, the power supply frame configured to be disposed in and constrained axially by a coupling assembly of a first downhole component and a second downhole component; an electronic component disposed in a second housing in the coupling assembly, the electronic component located external to the power supply frame; and a connector configured to transmit electric power from the power supply to the electronic component to supply electrical power to the electronic component.
A method of coupling downhole components includes: disposing a power supply in a first housing of a power supply frame, the power supply frame configured to isolate the power supply from downhole fluids; disposing the power supply frame in a coupling assembly of a first downhole component and a second downhole component; electrically connecting the power supply to an electronic component disposed in a second housing in the coupling assembly via an electrical connector disposed at the power supply frame, the electronic component configured to facilitate transmission of signals between the first downhole component and the second downhole component; and coupling the first downhole component to the second downhole component and constraining the power supply frame by the coupling assembly, wherein coupling includes communicatively connecting the first downhole component to the second downhole component via the electronic component and the power supply frame.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
There is provided an electronic housing assembly for use with downhole components, such as downhole tools, drill pipes and subassemblies. The assembly includes an electronics frame to house electronic components such as repeater electronics within a pressure-sealed and mechanically robust frame that can be mounted at, near or within a coupling configuration (e.g., the pin and/or box portion of a pin-box connector). The assembly also includes an external power supply configured to be disposed at, near or within the coupling configuration. In one embodiment, the external power supply is disposed in a separate frame or housing that is electrically connected to the electronics housing. In one embodiment, a power supply housing is disposed adjacent to the electronics housing within a coupling configuration, e.g., a bore-back section of a pin-box connection. The power supply may be connected to the electronics frame via at least one suitable connection, such as a capacitive, inductive, resonant and/or galvanic connection.
Referring to
The string 12 includes at least one string component, such as a pipe segment 14, having a first end 16 and a second end 18. An inner bore or other conduit 20 extends along the length of each segment 14 to allow drilling mud or other fluids to flow therethrough. A communication conduit 22 is located within the segment 14 to provide protection for electrical, optical or other conductors to be disposed along the segment 14. Although the string component is described as a pipe segment, it is not so limited. The string component may be any type of downhole component or carrier that includes a coupling mechanism for coupling the downhole component to another component.
The term “carrier” as used herein means any device, device component, combination of devices, media and/or member that may be used to convey, house, support or otherwise facilitate the use of another device, device component, combination of devices, media and/or member. Exemplary non-limiting carriers include wireline or logging-while-drilling tools, wire pipe, drill strings of the jointed pipe type and any combination or portion thereof. Other carrier examples include casing pipes, wirelines, wireline sondes, slickline sondes, drop shots, downhole subs and BHA's.
The segment 14 includes a coupling assembly having at least one of a first coupling 24 and a second coupling 26. The first coupling 24 includes a male coupling portion 28 having an exterior threaded section, and is referred to herein as a “pin” 24. The second coupling 26 includes a female coupling portion 30 having an interior threaded section, and is referred to herein as a “box” 26.
The pin 24 and the box 26 are configured so that the pin 24 can be disposed within the box 26 to affect a fixed connection therebetween to connect the segment 14 with an adjacent segment 14 or other downhole component. In one embodiment, the exterior of the male coupling portion 28 and the interior of the female coupling portion 30 are tapered along the length of the segment 14 to facilitate coupling. Although the pin 24 and the box 26 are described has having threaded portions, the pin 24 and the box 26 may be configured to be coupled using any suitable mechanism, such as bolts or screws or an interference fit.
In the embodiment shown in
As demonstrated in
In the embodiment of
In one embodiment, the housing assembly 40 is not adhered to or rotationally fixed within the bore-back 46, although the housing assembly 40 can be adhered or fixed if desired.
The frames 42 and 44, which in this embodiment are of a generally cylindrical shape (although embodiments are not limited to a particular shape) define a fluid conduit 52, which may be in the form of an inner or central bore, that provides fluid connection between the bores 20 of the string segments 14. The fluid conduit 52, in one embodiment, is a cylindrical central conduit having a diameter that is at least substantially equal to the diameter of the bores 20, although the conduit 52 can have a smaller diameter or have any shape or diameter suitable to transmit fluid between the segments 14. The frames 42 and 44 also include an outer surface (e.g., a cylindrical surface) that is configured to fit within the bore-back 54.
Although the power supply is described in
It is noted that the power supply frame 44 may have a similar configuration as that shown in
In one embodiment, the electronics frame 42 and/or the power supply frame 44 includes two or more parts or frame elements made from a high strength material (e.g. alloy steel or superalloy), i.e., a material that can withstand temperature, pressure, fluid and operational conditions experienced downhole. The frame elements are joined together to encapsulate the electronic components and/or power supply and isolate the electronic components and/or power supply from borehole fluids and other environmental conditions. As described herein, borehole fluids may include various liquids, gases, mixtures or liquids and gases and flowable solids. Exemplary fluids include water, hydrocarbons, drilling fluids, stimulation fluids, air and other gases, foams, sealing fluids and others.
In one embodiment, the frame elements are mechanically joined together by a permanent mechanical joining, such as a weld or an adhesive. Exemplary welding methods include laser or electron beam welding. As described herein, “permanently joined” is defined as being joined such that the frame elements are mechanically joined via a connection that forms at least a fluid-tight seal between the elements without including a feature (e.g., bolts) that provides a mechanism for disconnecting the elements.
The main body 64 of the electronics frame 42 is joined to a second frame element, which in this embodiment is configured as a sleeve 72 that covers and protects electronic components in, for example, the cavities 66.
The power supply frame 44 includes a support structure or main body 74 that includes one or more channels 76 configured to retain a wire or other conductor to electrically connect the electronics frame 42 to the pipe segment (e.g., pin or box). One or more retaining elements such as one or more pockets 78 are configured to retain a power supply such as a battery. The main body 74 is configured to electrically connect the power supply to the electronics retained in cavity 66. In one embodiment, the power supply and electronics are connected via the channels 68 and 76.
In the embodiment of
The electronics frame 42 is connected or coupled to the power supply frame 44, in this embodiment, via a permanent joining technique such as bonding or welding. For example, the frames 42 and 44 are welded via one or more welds 84 that provide a fluid-tight seal between the electronics frame 42 and the power supply frame 44. The mechanisms or features used for connecting or coupling the frames 42 and 44 are not limited to those described herein. For example, the frames 42 and 44 may be connected via a removable connection, such as one or more bolts or screws. In another example, the frames 42 and 44 are held in contact due to the coupling mechanism of the downhole components, such as the pin-box configuration of
In one embodiment, the second frame element is configured as a portion of the box, pin or other coupling mechanism. For example, instead of the secondary frame element being a sleeve, cover, inlay or other element that is welded to the main body 64 and/or the main body 74 prior to insertion into the pin-box connector, the main body 64 and/or 74 may be welded or joined to a surface in the pin or box. An exemplary surface is a surface of the box bore-back.
In one embodiment, one or more orientation mechanisms are included to ensure that the electronics frame 42 is rotationally oriented relative to the power supply frame 44 so that the proper electrical connection is achieved. For example, as shown in
In addition to the mechanical connection described above, the electronics frame 42 and the power supply frame 44 are electrically connected via a suitable electrical connection. In the embodiment shown in
In one embodiment, the frame 42 and/or the frame 44 includes fixation elements configured to hold the housing assembly 44 in a fixed position, e.g., a fixed rotational position, relative to the pipe segment(s) 14. For example, grooves or recesses may be included in one of the housing assembly 44 and the pipe segment (e.g., the box bore-back interior surface) that are configured to engage corresponding protrusions in the other of the housing assembly 44 and the pipe segment. Other fixation element embodiments may include bolts, screws and other forms of fit elements. Any type of fixation element or mechanism may be used, including interference fit configurations, gluing, welding and bonding. As discussed above, the tube 90 or other type of electrical connection may be used as a fixation element.
In one embodiment, a length adjustment element is included to conform the assembly 40 the bore back or other portion of the pipe segment. For example, the length adjustment element is a cylindrical element such as a gasket 106 having an axial length that results in a desired length of the housing assembly 40. The adjustment element may have a fixed length or may be adjustable to change the length of the assembly 40 as desired.
One embodiment of a method 110 of manufacturing an electronic housing assembly, coupling downhole components and/or performing a downhole operation is shown in
In the first stage 111, electronics are disposed or assembled in a coupling mechanism. The electronics may be attached or mounted directly to the coupling mechanism or may be disposed in a retaining structure such as the electronics frame 42.
In the second stage 112, a power supply is disposed in a retaining structure such as the power supply frame 44 and electrically connected to the electronics. An exemplary power supply retaining structure includes a main body having recesses or pockets to retain the power supply (e.g., a battery), and the power supply retaining structure is assembled by welding or otherwise joining a sleeve or other protective structure to the main body to isolate the power supply.
In the third stage 113, a first downhole component is coupled to a second downhole component. As described above, in one example, the electronics frame 42 and/or the power supply frame 44 are inserted into the box bore-back 46, and the pin and box are assembled to encapsulate and axially restrict the electronics frame 42 and/or the power supply frame 44. In other embodiments, the power supply frame 44 is inserted into the coupling assembly and electrically connected to electronics incorporated into the coupling assembly and/or one or more downhole components.
The coupling assembly is assembled around the electronics frame 42 and/or the power supply frame 44 to constrain the frame 42 and/or frame 44 therein. The coupling assembly may hold the electronics frame 42 and the power supply frame 42 in physical or mechanical contact, and may also hold the frames in electrical contact. For example, the pin end of a first component is inserted into the box end of a second component, and the pin is rotated to engage the threaded portion of the box. As shown in the example of
In the fourth stage 114, the first and second downhole components (e.g., segments 14) are lowered into a borehole. The segments 14 may be lowered into the borehole during or after a drilling, completion, measurement or other downhole operation. Additional segments 14 may be connected together via, e.g., respective pins 24 and boxes 26 including a frame 40 to further lengthen the string and lower the string 12 into the borehole.
The apparatuses and methods described herein provide various advantages over existing methods and devices. For example, the frames provide highly reliable housing and sealing of electronic and power supply components under high mud pressure (e.g. 30000 psi) in an inner bore as well as in the annulus and on the outer diameter of downhole equipment.
Connection between downhole components can be relatively easily achieved, as the frame(s) can be easily mounted, axially fixed and dismounted within the bore-back or other portion of a coupling assembly. In addition, assembly of the frame(s) within the coupling assembly, in some embodiments, does not require angular positioning. Furthermore, the power supply frame can be easily mounted within a coupling mechanism to provide an easy exchangeable energy source.
In support of the teachings herein, various analyses and/or analytical components may be used, including digital and/or analog systems. The system may have components such as a processor, storage media, memory, input, output, communications link (wired, wireless, pulsed mud, optical or other), user interfaces, software programs, signal processors (digital or analog) and other such components (such as resistors, capacitors, inductors and others) to provide for operation and analyses of the apparatus and methods disclosed herein in any of several manners well-appreciated in the art. It is considered that these teachings may be, but need not be, implemented in conjunction with a set of computer executable instructions stored on a computer readable medium, including memory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, hard drives), or any other type that when executed causes a computer to implement the method of the present invention. These instructions may provide for equipment operation, control, data collection and analysis and other functions deemed relevant by a system designer, owner, user or other such personnel, in addition to the functions described in this disclosure.
One skilled in the art will recognize that the various components or technologies may provide certain necessary or beneficial functionality or features. Accordingly, these functions and features as may be needed in support of the appended claims and variations thereof, are recognized as being inherently included as a part of the teachings herein and a part of the invention disclosed.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
