Downhole Inductive Coupler Sealing and Shielding Against Attenuation
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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, and existing inductive coupler systems are affected by high loads, harsh conditions, and stray magnetic fields, leading to reduced performance and increased attenuation.
Innovation Solution
An inductive data transmission system featuring an annular block with a ferrite circular channel and a conductive wire coil, housed within a polymer block that fits into a drill pipe joint, which includes a gasket for sealing and a shield to prevent stray electromagnetic interference, enhancing the electromagnetic field and reducing losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inductive couplers are used in wired pipe telemetry systems, then data transmission rate is improved, but attenuation increases and bandwidth decreases due to stray magnetic fields
Solution Approach 1:
The patent introduces a shield made of magnetically conductive electrically insulating material that captures and redirects stray magnetic fields. Instead of allowing these fields to cause losses, the shield channels them through a designated path, converting the harmful stray fields into useful magnetic flux that still contributes to the coupling between drill pipes while reducing attenuation.
Solution Approach 2:
The shield acts as an intermediary element between the inductive coupler and the surrounding environment. It mediates the interaction between the magnetic field and stray fields by providing a controlled path for magnetic flux, thereby reducing the harmful effects of stray fields on signal attenuation while maintaining data transmission effectiveness.
2Productivity
If inductive couplers are used in wired pipe telemetry systems, then data transmission rate is improved, but performance deteriorates under high loads and harsh downhole conditions
Solution Approach 1:
The shield is constructed from composite material that is both magnetically conductive and electrically insulating. This composite property allows the shield to guide magnetic fields while preventing electrical short circuits and corrosion, thereby maintaining reliable operation under harsh downhole conditions including high loads, moisture, and corrosive environments.
Solution Approach 2:
The shield is designed as a thin-walled structure that can flex and adapt to the mechanical stresses and dimensional changes that occur under high loads and temperature variations. This flexibility allows the shield to maintain its protective function and magnetic field guidance capability without fracturing or losing effectiveness under harsh downhole conditions.
3Productivity
If inductive couplers are exposed to stray magnetic fields, then data transmission capability is improved, but losses increase due to extended fields into unsuitable materials
Solution Approach 1:
The shield captures stray magnetic fields that would otherwise extend into unsuitable materials and cause losses. By redirecting these fields through a controlled magnetic path, the shield converts what would be energy losses into useful magnetic flux that maintains coupling between drill pipes, thereby reducing overall losses while preserving data transmission capability.
Solution Approach 2:
The shield serves as an intermediary that prevents direct interaction between stray magnetic fields and unsuitable materials. It provides a controlled interface that guides magnetic flux through appropriate pathways, eliminating the harmful extension of fields into materials that would cause energy losses while maintaining the necessary magnetic coupling for data transmission.
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 solution provides a more efficient and reliable data transmission system by minimizing attenuation and maintaining performance even in harsh downhole conditions, enabling faster and more accurate data transfer.
Implementation Method 1
converting the electrical signal to a magnetic field upon leaving the first wired pipe using an inductive transducer
Implementation Method 2
a ferrite circular channel arranged around the interior of the block. The ferrite covers the sides and bottom of the channel
Implementation Method 3
The pipes are torqued together sufficiently that the shoulders produce a fluid tight seal preventing the passage of downhole fluids
Data Source
AI summary
An annular block of polymer comprising an inductive coupler assembly configured to fit within a groove in the shoulder of a drill pipe joint. The assembly comprises a ferrite channel arranged around the interior of the block. At least one turn of a conductive wire is deposed within the channel. The block comprises a bumper comprising jutting from the block. The block comprises internal void openings adjacent its vertical side surfaces. A void opening is disposed proximate the bumper. The block further comprises an internal gasket partially extending from the bottom surface of the block. The external portion of the gasket being formed to fit within a gasket seat in the bottom of the groove. The wire passes through the gasket as it exits the block. When the block is installed into the groove, the gasket seals the wire and the block's components from the downhole environment.