Surface communication apparatus and method for use with drill string telemetry

Abstract

A system for bidirectional communication between the downhole equipment and a processor subsystem at the earth's surface, including: a section of wired drill pipes comprising at least the upper portion of a string of drill pipes, and forming at least a portion of a bidirectional communication link between downhole equipment and the top of the string of drill pipes; a drive string portion of the drill string, mechanically coupleable with the topmost wired drill pipe; a drive mechanism mechanically coupleable with said drive string portion, for rotating the drill string; a first wireless transceiver subsystem mounted on the drive string portion of the drill string, for rotation in conjunction with the drill string; a cable, electrically coupled between the top joint of the topmost wired drill pipe and the first transceiver subsystem; and a second wireless transceiver subsystem coupled with the uphole processor subsystem, the second wireless transceiver subsystem communicating bidirectionally with the first wireless transceiver subsystem.

1 . For use in an operation of drilling an earth borehole using: a drilling rig, a drill string having its generally upper end mechanically coupleable with and suspendable from the drilling rig, and downhole equipment on the drill string, a system for bidirectional communication between the downhole equipment and a processor subsystem at the earth's surface, comprising: 
 a section of wired drill pipes comprising at least the upper portion of the string of drill pipes, and forming at least a portion of a bidirectional communication link between the downhole equipment and the top of the string of drill pipes;    a drive string portion of the drill string, mechanically coupleable with the topmost wired drill pipe;    a drive mechanism mechanically coupleable with said drive string portion, for rotating the drill string;    a first wireless transceiver subsystem mounted on said drive string portion of the drill string, for rotation in conjunction with the drill string;    a cable, electrically coupled between the top joint of said topmost wired drill pipe and said first transceiver subsystem; and    a second wireless transceiver subsystem coupled with said uphole processor subsystem, said second wireless transceiver subsystem communicating bidirectionally with said first wireless transceiver subsystem.    
   
   
       2 . The system as defined by  claim 1 , wherein said cable comprises a plurality of wires.  
   
   
       3 . The system as defined by  claim 2 , wherein said section of wired drill pipe has inductive couplers at the joints of each pipe, and wherein said cable is electrically coupled to the top joint of said topmost wired drill pipe by an inductive coupling.  
   
   
       4 . The system as defined by  claim 1 , wherein said first transceiver subsystem includes a first antenna subsystem, and said second transceiver subsystem includes a second antenna subsystem.  
   
   
       5 . The system as defined by  claim 4 , wherein said first antenna subsystem comprises a plurality of antennas.  
   
   
       6 . The system as defined by  claim 4 , wherein said second antenna subsystem comprises a plurality of antennas.  
   
   
       7 . The system as defined by  claim 1 , wherein said drive string portion of the drill string comprises a kelly.  
   
   
       8 . The system as defined by  claim 7 , wherein said drive mechanism comprises a rotating table with a kelly bushing that engages said kelly.  
   
   
       9 . The system as defined by  claim 1 , wherein said drive string portion of the drill string comprises a top drive sub.  
   
   
       10 . The system as defined by  claim 9 , wherein said drive mechanism comprises a top drive that engages said top drive sub.  
   
   
       11 . The system as defined by  claim 7 , wherein said drive string portion of the drill string further comprises a saver sub between said kelly and said topmost wired drill pipe.  
   
   
       12 . The system as defined by  claim 9 , wherein said drive string portion of the drill string further comprises a saver sub between said top drive sub and said topmost wired drill pipe.  
   
   
       13 . The system as defined by  claim 4 , wherein an antenna of said first antenna subsystem and said first wireless transceiver subsystem are mounted at substantially the same position on said drive string portion of the drill string.  
   
   
       14 . The system as defined by  claim 4 , wherein an antenna of said first antenna subsystem and at least part of said first wireless transceiver subsystem are mounted at respectively different positions on said drive string portion of the drill string.  
   
   
       15 . The system as defined by  claim 4 , wherein said first antenna subsystem includes a plurality of antennas at different azimuthal positions on said drive string portion of the drill string.  
   
   
       16 . The system as defined by  claim 4 , wherein said second antenna subsystem includes a plurality of spaced apart antennas.  
   
   
       17 . The system as defined by  claim 1 , further comprising an electric generator for generating electric power for use by said first transceiver subsystem, said electric generator including a rotating generator component that is mounted on said drive string portion of the drill string and a stationary generator component that is mounted on a stationary portion of the drilling rig.  
   
   
       18 . The system as defined by  claim 17 , wherein said stationary generator component comprises a ring of magnets.  
   
   
       19 . The system as defined by  claim 18 , wherein said rotating generator component comprises at least one stator coil.  
   
   
       20 . The system as defined by  claim 19 , wherein said rotating generator component and stationary generator component are disposed in close proximity such that magnetic flux from said ring of magnets crosses said at least one stator coil.  
   
   
       21 . The system as defined by  claim 17 , further comprising a rechargeable battery charged by said electric generator, said battery storing said electric power for use by said first transceiver subsystem.  
   
   
       22 . The system as defined by  claim 20 , further comprising a rechargeable battery charged by said electric generator, said battery storing said electric power for use by said first transceiver subsystem.  
   
   
       23 . The system as defined by  claim 21 , wherein said rechargeable battery is mounted in conjunction with said first transceiver subsystem for rotation in conjunction with the drill string.  
   
   
       24 . For use in an operation of drilling an earth borehole using: a drilling rig, a drill string of drill pipes having its generally upper end mechanically coupleable with and suspendable from the drilling rig, a drive string portion of the drill string, mechanically coupleable with the topmost drill pipe of said drill string, and a drive mechanism mechanically coupleable with said drive string for rotating the drive string and the drill string; a system for generating electric power in the region of the drive string, comprising: an electric generator that includes a rotating generator component that is mounted on said drive string for rotation therewith, and a stationary generator component that is mounted on a stationary portion of the drilling rig, said rotating generator component producing electric power in the region of said drive string.  
   
   
       25 . The system as defined by  claim 24 , wherein said stationary generator component comprises a ring of magnets.  
   
   
       26 . The system as defined by  claim 25 , wherein said rotating generator component comprises at least one stator coil.  
   
   
       27 . The system as defined by  claim 26 , wherein said rotating generator component and stationary generator component are disposed in close proximity such that magnetic flux from said ring of magnets crosses said at least one stator coil.  
   
   
       28 . The system as defined by  claim 24 , further comprising a rechargeable battery charged by said electric generator, and mounted on said drill string.  
   
   
       29 . The system as defined by  claim 24 , further comprising a drill telemetry subsystem forming at least a portion of a communication link between downhole equipment on the drill string and an uphole processor subsystem; and wherein said electric power from said electric generator is adapted to provide power for said communication link.  
   
   
       30 . The system as defined by  claim 27 , further comprising a drill telemetry subsystem forming at least a portion of a communication link between downhole equipment on the drill string and an uphole processor subsystem; and wherein said electric power from said electric generator is adapted to provide power for said communication link.  
   
   
       31 . The system as defined by  claim 24 , further comprising: 
 a system for bidirectional communication between a downhole equipment and a processor subsystem at the earth's surface, comprising a section of wired drill pipes comprising at least the upper portion of the string of drill pipes, and forming at least a portion of a bidirectional communication link between the downhole equipment and the top of the string of drill pipes; a first wireless transceiver subsystem mounted on said drive string portion of the drill string, for rotation in conjunction with the drill string, said first wireless transceiver subsystem being coupled with said section of wired drill pipe; and a second wireless transceiver subsystem coupled with said uphole processor subsystem, said second wireless transceiver subsystem communicating bidirectionally with said first wireless transceiver subsystem; and    wherein said electric power from said electric generator is adapted for use by said first transceiver subsystem.    
   
   
       32 . For use in an operation of drilling an earth borehole using: a drilling rig, a drill string having its generally upper end mechanically coupleable with and suspendable from the drilling rig, and downhole equipment on the drill string, a method for bidirectional communication between the downhole equipment and a processor subsystem at the earth's surface, comprising the steps of: 
 providing a drill string telemetry system comprising at least the upper portion of the string of drill pipes, and forming at least a portion of a bidirectional communication link between the downhole equipment and the top of the string of drill pipes;    providing a drive string portion of the drill string, mechanically coupleable with the topmost drill pipe;    providing a drive mechanism mechanically coupleable with said drive string portion, for rotating the drill string;    providing a first wireless transceiver subsystem mounted on said drive string portion of the drill string, for rotation in conjunction with the drill string;    providing a cable, electrically coupled, at the top joint of said topmost drill pipe, between said drill string telemetry system and said first wireless transceiver subsystem; and    providing a second wireless transceiver subsystem coupled with said uphole processor subsystem, said second wireless transceiver subsystem communicating bidirectionally with said first wireless transceiver subsystem.    
   
   
       33 . The method as defined by  claim 32 , further comprising the step of providing, at about the top of the drill string, sensors for measuring parameters relating to the drilling operation, and wherein signals from said sensors are coupled with said cable.  
   
   
       34 . The method as defined by  claim 33 , wherein said step of providing said sensors comprises providing at least one sensor selected from the group consisting of a temperature sensor, pressure sensor, mud flow sensor, noise sensor, vibration sensor, torque sensor, acceleration sensor, and rotation sensor.  
   
   
       35 . The method as defined by  claim 32 , further comprising the step of encrypting signals communicated bidirectionally between said first wireless transceiver subsystem and said second wireless transceiver subsystem.  
   
   
       36 . The method as defined by  claim 32 , further comprising the step of compressing signals communicated bidirectionally between said first wireless transceiver subsystem and said second wireless transceiver subsystem.  
   
   
       37 . For use in an operation of drilling an earth borehole using: a drilling rig, a drill string of drill pipes having its generally upper end mechanically coupleable with and suspendable from the drilling rig, a drive string portion of the drill string, mechanically coupleable with the topmost drill pipe of said drill string, and a drive mechanism mechanically coupleable with said drive string for rotating the drive string and the drill string; a method for generating electric power in the region of the drive string, comprising the steps of: providing a power generating unit having a first component that is mounted on said drive string for movement therewith; and producing power in the region of said drive string from movement of said first component.  
   
   
       38 . The method as defined by  claim 37 , wherein said step of producing power comprises producing electric power from vibration of said first component.  
   
   
       39 . The method as defined by  claim 37 , further comprising mounting a second component on a stationary portion of the drilling rig, and wherein said step of producing power comprises producing power from relative movement of said first component with respect to said second component.  
   
   
       40 . The method as defined by  claim 39 , wherein said relative movement comprises rotation of said first component with respect to said second component.