Toroidal Coil Wireless Communication in Downhole Wells
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Solution Overview
Problem
Conventional wired communication systems in downhole equipment of gas wells are prone to failures due to damaged electrical cables, leading to pump system failures, increased costs, and production losses, particularly in coal seam gas wells where intermittent operation and water level monitoring are critical.
Innovation Solution
A wireless communication system using toroidal coils to transmit data between downhole and surface equipment, where a data signal applied to one toroidal coil induces currents in a conductive component, which are then sensed by another toroidal coil, eliminating the need for physical cables and enabling bidirectional data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired communication systems are used for downhole equipment, then data transmission can be achieved, but the system is prone to failures due to damaged electrical cables
Solution Approach 1:
The patent replaces the mechanical wired communication system with an electromagnetic field-based wireless communication system. Toroidal coils generate electromagnetic fields that induce currents in conductive components (rod/tubular) to transmit data signals without physical cable connections, thereby eliminating cable damage issues while maintaining reliable data transmission.
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary medium for data transmission. The toroidal coils generate electromagnetic fields that serve as the mediator between the transmitter and receiver, allowing data to be transmitted through the conductive component without direct physical cable contact, thus improving reliability.
2Reliability
If wireless communication using toroidal coils is implemented, then cable damage is eliminated, but the device complexity increases
Solution Approach 1:
The patent makes the conductive component (rod/tubular) serve multiple functions: it acts as both a structural element supporting the pump system and as a transmission medium for wireless communication. This multi-functionality reduces overall system complexity by eliminating the need for separate communication cables and components.
Solution Approach 2:
The existing conductive components of the pump system serve the dual purpose of mechanical support and data transmission. The system uses its own structural elements for communication purposes, eliminating the need for additional dedicated communication infrastructure and thereby reducing complexity.
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
This solution reduces the risk of pump system failures, minimizes production losses, and lowers operational costs by providing reliable, cable-free communication for monitoring and controlling downhole conditions, allowing for continuous and efficient gas production.
Implementation Method 1
a data signal applied to one toroidal coil induces currents in the axially extending component, and these currents induce a voltage in another toroidal coil which can be sensed to receive the data
Implementation Method 2
A first toroidal transformer is positioned around the second structural member... A transmitter is coupled to the first toroidal transformer and is configured to generate a data signal... when the data signal is applied to the first toroidal transformer, a corresponding electrical current is induced in the first electrical circuit, which then induces the data signal on the second toroidal transformer
Data Source
AI summary
Systems and methods for communicating between surface equipment and a downhole tool installed in a well. First and second toroidal transformers are positioned around an inner one of a pair of coaxial structural members of a well completion (e.g., a pump rod and tubular, or a tubular and a well casing) which are electrically coupled to form an electrical circuit. A transmitter generates a data signal which is applied to the first toroidal transformer, causing a corresponding electrical current to be induced in the circuit, which then induces the data signal on the second toroidal transformer. A receiver coupled to the second toroidal transformer receives the data signal induced on the second toroidal transformer. The transmitter and receiver may be components of transceivers that may communicate bidirectionally. Additional toroidal coils and transceiver may be provided to communicate with equipment at additional locations in the well.