System and method for manufacturing electrically isolated connection for electromagnetic gap sub assembly

Abstract

A gap sub assembly and methods for using the gap sub provide an electrical isolating joint that is mechanically strong enough to withstand the rigors of drilling environments, resistant to environmental effects (heat, corrosive liquids and gases, and high pressures), and maintainable. The gap sub assembly provides a male member and a female member that may be connected together, wherein a non-conductive material is applied between the two at the attachment points. A locking ring or collar affixes to both male and female members to prevent back off while drilling and preserving the electrical isolation of the gap joint. Non-conductive material may be injected between the locking ring and one or more of the male or female members.

What is claimed is: 
     
         1 . A method for assembling a gap sub assembly comprising:
 sliding a locking ring onto a first tubular component, wherein first tubular component has a first connecting end with a first set of anti-torsion features that mate with a third set of anti-torsion features provided by the locking ring to minimize rotation of the first tubular component relative to the locking ring;   coupling the first tubular component to a second tubular component having a second connecting end connectable to the first connecting end, wherein the second tubular component has a second set of anti-torsion features; and   mating a fourth set of anti-torsion features provided by the locking ring to the second set of anti-torsion features of the second tubular component.   
     
     
         2 . The method of  claim 1 , further comprising injecting a non-conductive material into an annular space between the second tubular component and the locking ring, wherein the non-conductive material also coats the first and second connecting ends, and the non-conductive material electrically isolates the second tubular component from the first tubular component. 
     
     
         3 . The method of  claim 2 , further comprising curing the non-conductive material, wherein the non-conductive material electrically isolates the second tubular component from the first tubular component. 
     
     
         4 . The method of  claim 3 , wherein the non-conductive material is a ceramic, epoxy, plastic, resin, Zenite material with glass fibre, or a combination thereof. 
     
     
         5 . The method of  claim 1 , wherein the first and second connecting ends are coated with a non-conductive material prior to coupling. 
     
     
         6 . The method of  claim 5 , wherein the non-conductive material is a ceramic, epoxy, plastic, resin, Zenite material with glass fibre, or a combination thereof. 
     
     
         7 . The method of  claim 1 , further comprising utilizing spacers to keep the locking ring locked in position, wherein the locking ring is made of a second non-conductive material. 
     
     
         8 . The method of  claim 7 , wherein the spacers keep the locking ring centralized in engagement with the second tubular component. 
     
     
         9 . The method of  claim 7 , wherein the second non-conductive material is a plastic. 
     
     
         10 . The method of  claim 9 , wherein the plastic is PEEK. 
     
     
         11 . The method of  claim 1 , wherein the first set of anti-torsion features are provided on an external surface of the first tubular component near the first connecting end. 
     
     
         12 . The method of  claim 1 , wherein the second set of anti-torsion features are provided on an external surface of the second tubular component near the second connecting end. 
     
     
         13 . The method of  claim 1 , wherein the third set of anti-torsion features are provided at a first end of the locking ring. 
     
     
         14 . The method of  claim 1 , wherein the fourth set of anti-rotation features are provided on an internal surface of the locking ring. 
     
     
         15 . The method of  claim 1 , wherein the locking ring is comprised of multiple rings that interlock together. 
     
     
         16 . The method of  claim 1 , wherein the first set of anti-torsion features of the first tubular component and the third set of anti-torsion features of the locking ring prevent rotation of 270 degrees or more when mated. 
     
     
         17 . The method of  claim 1 , wherein the first set of anti-torsion features of the first tubular component and the third set of anti-torsion features of the locking ring prevent rotation of 180 degrees or more when mated. 
     
     
         18 . The method of  claim 1 , wherein the first set of anti-torsion features of the first tubular component and the third set of anti-torsion features of the locking ring prevent rotation of 90 degrees or more when mated. 
     
     
         19 . The method of  claim 1 , wherein the first and third set of anti-torsion features are grooves and splines. 
     
     
         20 . The method of  claim 1 , wherein the second and fourth set of anti-torsion features are castellations and castellation slots.