Downhole Inductive Coupler With MCEI Ferrite Ring for Low-Loss Telemetry
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Solution Overview
Problem
Downhole drilling operations face challenges in rapidly and reliably transmitting data from downhole measuring tools to the surface due to the limitations of mud pulse telemetry, including slow data transmission rates and signal losses caused by stray magnetic fields and conductive metals in the drill pipe.
Innovation Solution
The use of an annular polymeric block with a magnetically conductive electrically insulating (MCEI) ferrite circular channel ring and MCEI particles, such as Fe and Mn based ferrite elements, to reduce signal losses across drill pipe connections by promoting magnetic coupling and minimizing the impact of stray magnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inductive transducers are used in wired pipe telemetry systems, then data transmission rate is improved, but signal losses increase due to stray magnetic fields and conductive metals
Solution Approach 1:
The patent introduces MCEI material as an intermediary substance between the inductive transducer and the conductive metal drill pipe. This material acts as a barrier that prevents stray magnetic fields from extending into the conductive metal, thereby reducing signal losses while allowing the inductive transducer to function effectively for high-rate data transmission
Solution Approach 2:
The patent uses MCEI (magnetically conductive electrically insulating) composite material that combines the properties of magnetic conductivity (to guide and contain magnetic fields) with electrical insulation (to prevent eddy current losses in conductive metals). This composite material property allows the system to achieve both high data transmission rates and reduced signal losses
2Reliability
If inductive transducers are used in wired pipe telemetry systems, then data transmission capability is improved, but attenuation increases due to stray magnetic fields
Solution Approach 1:
The patent converts the potentially harmful stray magnetic fields into beneficial contained magnetic flux by using MCEI material. The material guides the magnetic fields in a controlled path, preventing them from causing harmful eddy currents in the drill pipe while maintaining effective magnetic coupling for data transmission
Solution Approach 2:
The MCEI material serves as an intermediary layer that mediates between the magnetic field generation and the conductive metal environment, transforming the interaction from harmful (stray fields causing attenuation) to beneficial (controlled magnetic coupling with reduced losses)
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution effectively reduces data and signal losses across drill pipe connections, enhancing the reliability and efficiency of data transmission in downhole drilling operations.
Implementation Method 1
The exposed top surface of the ferrite circular channel ring may promote magnetic coupling between opposed ferrite circular channel rings when pipe joints are made up
Implementation Method 2
a conductive wire coil having one or more turns may run along the annular interior channel producing an inductive coupler suitable for transmitting data and power across the drill pipe joints
Data Source
AI summary
An inductive coupler system comprising an annular groove formed in the shoulder of a drill pipe. The annular groove housing an annular block comprising an inductive coupler assembly molded therein comprising a magnetically conductive electrically insulating (MCEI) ferrite ring forming an annular interior channel and a conductive wire with one or more turns running along the annular interior channel. The annular block comprising a polymer comprising a volume of micron (mμ) and submicron (nm) size MCEI elements. The MCEI elements comprising Fe and Mn. The annular block comprising a planar top surface, bottom surface, and the respective surfaces being joined by inside and outside peripheral side surfaces. The outside peripheral side surface comprising a protruding bumper comprising a dimple molded therein. The annular block further comprising a gasket comprising an axial pathway through which a portion of the conductive wire passes as the conductive wire exits the annular block.