WO2022094144A1 - Downhole power and data transfer - Google Patents
Downhole power and data transfer Download PDFInfo
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- WO2022094144A1 WO2022094144A1 PCT/US2021/057140 US2021057140W WO2022094144A1 WO 2022094144 A1 WO2022094144 A1 WO 2022094144A1 US 2021057140 W US2021057140 W US 2021057140W WO 2022094144 A1 WO2022094144 A1 WO 2022094144A1
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- signal
- power transferring
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/02—Couplings; joints
- E21B17/028—Electrical or electro-magnetic connections
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
- G01V11/00—Prospecting or detecting by methods combining techniques covered by two or more of main groups G01V1/00 - G01V9/00
- G01V11/002—Details, e.g. power supply systems for logging instruments, transmitting or recording data, specially adapted for well logging, also if the prospecting method is irrelevant
Definitions
- Fig. 1 is an illustration of a block diagram illustrating an example of facilitating communication between a computing device and a remote computing device.
- Fig. 2 is an illustration of a block diagram illustrating an example of a user interface.
- Fig. 3 is an illustration of a block diagram of an apparatus for power and data transfer.
- Fig. 4 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 5 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 6 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 7 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 8 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 9 is an illustration of a block diagram of an apparatus for power and data transfer.
- Fig. 10 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals.
- Fig. 11 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals.
- Fig. 12 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals.
- Fig. 13 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals.
- Fig. 14 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 15 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
- Fig. 16 is an illustration of a method for creating a closeout structure.
- Fig. 17 is an illustration of a method for creating a closeout structure.
- Fig. 17 is an illustration of a method for creating a closeout structure. [019] Fig.
- FIG. 18 is an illustration of a method for creating a closeout structure.
- FIG. 19 is an illustration of a side view of a closeout structure.
- Fig. 20 is an illustration of a side view of a closeout structure.
- Fig. 21 is an illustration of a side view of a closeout structure.
- Fig. 22 is an illustration of a side view of a closeout structure.
- Figs. 23A – 23J are illustrations of closeout structure during various stages of creation.
- Figs. 24A – 24G are illustrations of a smeared conductor.
- Figs. 25A – 25F are illustrations of a treaded conductor.
- Another method includes the use of wireline services, where a conductor is lowered into the well with tools physically connected to it.
- the problem with using this wireline service is that it can only allow for real-time data transfer at finite intervals, as the wireline is not a permanent or long-standing installation of the well. Furthermore, the use of the wireline is economically limiting as it is an expensive and time-consuming addition to the well creation process.
- fiber optic cables can be used directly by acting as continuous sensors and by delivering the data to the surface. The armored cables are deployed like wireline, where they are unspooled and clamped to the casing string as it is assembled and lowered into the well.
- fiber optics are limited due to being the most expensive data acquisition technique available in the oil industry as well as requiring separate crews to install them. Furthermore, fiber optics work best as continuous strands and any connection points between the two cables will significantly degrade the obtainable signal. Lastly, fiber optic cables are a temporary data acquisition technique as the cable cannot be left in the well for continuous data reading. While acquiring data for a finite interval has some benefits, it would be ideal to have continuous, long-term monitoring of downhole assets and environments. [033] Finally, another data collection method is through utilizing a sensor on a tool itself that logs information to a memory or hard drive device. Once the tool is pulled out of the well and back to surface, the data is then downloaded and read at that time.
- a very high area to length aspect ratio isolated cavity is provided in such a way that the strength of the original object (e.g., a tubular structure) is not significantly altered. This cavity will also deform with the original object, allowing utilization in extreme environments. This cavity does not require high aspect drilling operations. This cavity is completely sealed and protected from the environment. This cavity can be populated with a large variety of components. Such a cavity has the effective final isolated voluminous geometry as would be present had two pipes been used, the exception being one has been created to be small enough to live within the wall of another.
- Maintaining the properties of the larger tube is crucial, as the oil and gas industry required extreme forces to be transferred with such tubes.
- the materials and geometries selected for these operations are often designed to be as close to failing as possible to reduce costs and increase performance.
- the structural performance margins on such a design are so small that the design of such a pocket is specialized and sophisticated enough to minimally impact this performance.
- the means of creating such a volume must be sufficiently inexpensive and predictable such that the added cost of including the volume is not too great. Once such an isolated volume has been created, many new opportunities present themselves. It is possible to add components to this volume during assembly so that the final system is complete after a joining process has been implemented. [035] For joining processes that require additional heat treat operations that may be too harsh for certain components, another procedure has been implemented.
- Very high aspect ratio components may be added to a high area to length aspect ratio cavity with specialized procedures. Wires are such a critically important feature that can have a large number of highly valuable goals. These procedures allow the addition of any number of conductors to a long, slim cavity. This procedure consists of using a rigid, slender beam to first pass through the volume, which is then used to pull the conductors through after. This allows the installation of heat sensitive components into an assembly that can otherwise be heat treated or welded. This manufacturing flexibility allows for additional joining processes to be used to create the cavities. These two technologies build off of one another for various use cases, but are robust and valuable enough to exist on their own. Additionally, a high area to length aspect ratio cavity may be used as a conduit to pass fluids with sufficient flow to power equipment.
- the architecture of a traditional drill string uses many fixed length casings attached with threaded connections.
- a geometric configuration is provided that allows a radially slim annular volume to exist in a threaded connection without significantly changing the design or increasing critical profile dimensions.
- This volume can be created by very simple changes to the dimensions of existing features. This simplicity maintains the original design intents of a complex threaded and even sealed interface. This simplicity drives also costs down significantly, which is a very important consideration when these features need to be so numerous.
- Such a volume can be located in a threaded connection at locations allowing highly precise alignment with as much clearance as desired. This volume can also be located in regions less susceptible to damage when the casings are being fit up and threaded together.
- the canted springs create a large number of high pressure contact points.
- the canted springs only require a few loops to remain geometrically stable.
- a design with sufficient conductors on either side of a canted spring allows an assembled spring to tolerate breakage in numerous locations to maintain very good contact. Additionally, the high contact pressure of a canted spring is capable of pushing through extremely viscous medium and thick oxide layers.
- a connection is provided that is capable of fitting within a radially slim annular volume. The electrical connection is completed when the connection is threaded together and any and all electrical contacts are axially aligned. Such a connection architecture creates as many independent conductive paths as desired. This lower cost allows the inclusion of multiple independent conductors, a key feature for increasing reliability and bandwidth.
- connection allows assembly onto an O-ring style groove to decrease radial dimension.
- a means to attach wires to electromechanical connector contacts with minimal geometric dimensions is also provided.
- This connection is of operating during severe bending and loading of the base pipes, a key feature of anything that expects to operate in such an environment. The temperatures present also have a drastic effect on what a final design is constructed of such that the system being capable of operation across the entire temperature range.
- a procedure is provided that incorporates specific geometrical features and traditionally utilized processes to create a small volume passage through transitions in a threaded pipe system. This pathway allows a connection from a very high area to length aspect ratio cavities to geometric configurations that allow a radially slim annular volume to exist in a threaded connection.
- This pathway gives enough flexibility to specific components to highly specific connections.
- the specific needs of each component segment may differ, so a means to allow multiple segments to connect and function together may be provider.
- Several features of both the existing connections and the augmented geometries were adapted to work with one another allows the use of manufacturing techniques to complete our design. Extending a closeout lid (e.g., a closeout structure) into the externally upset section of a threaded connection does more than lower the stress on the closeout lid under loading. This transition also creates a thicker lid segment, allowing the passage to vary in height and radius. This increase provides the necessary angle to make a traditional drill process possible.
- a closeout process is provided that can be used in close proximity to heat sensitive components such as electronics and with components that undergo significant deformation in service.
- This procedure allows a base material made of a casing-optimal material to be used with a material that maintains excellent elasticity and strength after welding and without the need for heat treatment.
- the resulting closeout structure is extremely resilient and can deform along with the base material.
- Such a design is desired when it is impossible to add sensitive components after a heat treatment due to geometric or operational constraints such as the final sealing of a lid designed to protect electronics.
- the combination of design slightness and performance such that the performance of the component is not significantly affected and the deformation tolerance such that performance envelopes and design architecture is maintained allows such a feature to be incorporated in such an extremely constrained and stressed component.
- a means to accurately detect and orient downhole tools to avoid or align with specific features such as very high area to length aspect ratio isolated cavity is provided. This system prevents perforation operations from penetrating features by providing a system of hardware, sensors and operations to accurately locate such features. Hardware features may already be present in the design, or can be added to a casing.
- An example of an existing hardware clocking feature would be the insulation surrounding copper wires providing a significantly different eddy current or ultrasonic signature from the surrounding materials.
- An example of an added clocking feature may be a radioactive tracer providing a radioactive signature that can be found with a directional detector.
- Traditional electrical wire consists of an electrical conductor surrounded by electrically insulative material. The extension of this is an electrical cable which is a single jacketed line consisting of two or more electrical conductors (wires) separated by insulative material, sometimes each coated with their own insulative jackets. The purpose of the wire is to maintain the continuity of a voltage potential, or the conductive path of electrical current from one electrical component to another.
- wires may provide power to, or pass signals between, electrical components and devices without allowing them to affect one another.
- This general philosophy maintains that electrically conductive materials separated by electrical insulators are able carry distinct signals over some distance in relatively close proximity to one another.
- a solid-state coating technology is provided that uses high speed particles to plastically deform and deposit them onto a substrate, creating a bond. Using this technology, deposit alternating layers of insulative and conductive materials on top of it, one or more conductive paths (wires) can be created on and/or within various bodies and/or geometries.
- the solid-state coating technology allows this process to occur in a non-destructive manner requiring only line of sight to the mating surfaces of the pipes, couplings, or other tubular bodies.
- a layer of the substrate material can then be used to join the surrounding substrate and closeout the body within which a network of conductors has been embedded allowing for no changes to the surface of a body or its material properties.
- continuity can be maintained from a conductor in one section of pipe (e.g., a tubular structure) to a conductor in another threaded into it, given the conductors’ exposed cross-sections embedded into each pipe are located at the same axial distance from the pipe center.
- the female coupling will be extended from the primary threading surface to create an additional electrical connection surface area and volume to house sensing devices, printed circuit boards, batteries, or other components.
- the electrical connection area will primarily be between the outer surface of the male pipe (e.g., a tubular structure) and the inner surface of the female coupling extension therefore ensuring that the pipe (e.g., a tubular structure) will always maintain intended mechanical performance by never penetrating through critical wall thickness of the pipe.
- the conductive coaxial trace will establish continuity of an electronic signal at the mating surface between the exposed cross-sections of the embedded wires.
- This electric conductor may be a wire.
- This electric conductor can also be fabricated by the following procedure: using cold-spray, or other deposition methods, by coating the trench floor and part-way up the sides with an electrical insulator such-as PEEK, ABS or PLA.
- an electrical insulator such-as PEEK, ABS or PLA.
- a conductive path or paths are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals.
- the above method may be repeated in order to create discrete conductors separated by insulative layers.
- a thin layer of insulation is then deposited atop the final conductor to electrically isolate it.
- An additional layer of insulation can be added for added strength and/or protection during the closeout operation (detailed later).
- a spring or assembly is inserted into a groove or volume created to ensure the electrical conductor can retract during the threading and assembly process, while also ensuring there is sufficient contact force when the threading and assembly is complete.
- a top the final layer of deposited insulative material the addition of a thin sheet of a metal, such as aluminum, stainless steel, or steel, is advisable to protect the conductive wire during, and aid in deposition during, the close out operation.
- the ‘closeout operation’ essentially replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded.
- the inner diameter of the female coupling (e.g., second tubular structure 304) and the male pipe (e.g., a first tubular structure 320) shall expose electrical communication points at varying length-wise positions which correspond to the radial position of the conductor laid in the groove/trench.
- each electrical conductor can be planned accordingly to interleave multiple connection points in any given area.
- cross sections of the conductor shall be left exposed, and elsewhere an insulative layer deposited over the metallic casing at the mating surfaces in order to electrically isolate the pipe from the conductive traces to be laid later.
- the processes detailed above should be used at all ends of interlocking casings or casings that are to interface with couplings, as to create a large surface area of unique conductance at the ends of casings and inside couplings to transmit signals between casings and couplings by depositing electrical traces via cold spray, laser powder deposition, ultrasonic welding, or other metallic additive manufacturing techniques.
- the extension of the female coupling can be used as housing volume to build in any device. Since this material may not affect the integrity or performance of the pipe, the amount of extra volume created by this extension can be used to house external measurement, communication, or other devices.
- the techniques disclosed herein provide for a permanent installation of data and power transfer capabilities in a well using the existing infrastructure, limiting complexities in implementation and allowing for long-term data acquisition.
- the solid-state coating technology embedded components are cables, electrical circuits, sensors, and leads which are hermetically integrated and mechanically locked sub-flush into the face of a metal structure such that these electrical components can perform their primary functionalities and be protected within the confines of the parent structure without sacrificing geometric and/or mechanical/structural requirements of the parent structure with which the embedded components are integrated into.
- the external metal wall on a surface of a pipe may be built upon by cold spraying (CS) high tensile steel powder to form a cavity that enables electronic components to be placed within that cavity and then sealed by a suitable resin polymer or metal that can then be fully sealed by a secondary CS of metal to that surface to mate the CS wall to the CS surface to form a hermitically seal that can withstand a shearing load that matches, or is superior, to the mechanical properties of the metal pipe.
- CS cold spraying
- This solid-state coating technology relies on a solid-state process, meaning it does not melt the added metal material, nor induce temperatures on the parent material/ electrical component that yield significant mechanical damage. Of the few solid-state metallic additive manufacturing processes, it is the most flexible in line-of-site, allowing for complex geometric augmentations without the requirement of a planar substrate surface to apply onto, such as an ultrasonic or friction stir weld adaptation of solid-state additive manufacturing. [056]
- This solid-state coating technology may use high speed metal particles to plastically deform and deposit them onto a substrate, creating a physical bond. In order to do so efficiently, it is important that the substrate be continuous and allow for a nozzle to remain at an orientation that is as near orthogonal to the substrate as possible at all times during the process.
- 23A – 23J the following details a method for safely protecting, hermetically sealing, and mechanically joining electrical circuits, cables, sensors, or other objects into a metal body or substrate 2301 (e.g., a substrate 2301 of a tubular structure), by first creating wide U shaped channel or chamfered filleted-groove 2302 which comprises of a flat base and angled walls by subtractive manufacturing or extrusion, as illustrated by Figs. 23A and 23B.
- the angle of this chamfer 2304 is to be no greater than 45 degrees from vertical to allow for line-of sight during the aforementioned closeout operation.
- a pocket 2305 is created, by subtractive manufacturing or extrusion, or build-up of additional material to create this profile 2305 via additive manufacturing within which a circuit, sensor, cable, or various object 2306 (e.g., signal or power transferring spring structures and/or signal or power transferring path structures) which will be housed, as illustrated by Figs.23C – 23E.
- a positive mold of the pocket/channel 2305 which can be created in a metal, composite, polymer, or ceramic, shall be manufactured as to fill any negative space surrounding the circuit, sensor, cable, or other object 2306 up to the flat area of the filleted-groove 2302.
- This positive mold 2307 may take many forms, such as a sheet metal box with flanged top filled with insulative material to suspend the object 2306, or metallic, composite, polymer, or ceramic additively manufactured to create the positive mold of the pocket/channel 2305 and negative cutout of the circuit, sensor, cable, or object 2306, as illustrated by Fig. 23F. Whatever the mold, the negative of the object 2306 to be embedded must be created for it to be securely housed. [059] An adhesive, epoxy or other sealant 2308 shall be used to affix the mold and object assembly (2306, 2307), or object 2306 itself if its geometry is amenable to the process, to the pocket and seal any gap between the metal body substrate 2301, and the mold or object itself 2307, as illustrated by Fig.
- a closeout e.g., creation of a closeout structure 302 of the assembly is performed with cold spray using metal, polymer, composite, or ceramic powder deposited over the filleted-groove 2302, designed in such a way that a spray nozzle is able to remain normal to all surfaces during this operation.
- the cold spray material can be machined to achieve a smooth finish by subtractive manufacturing techniques if desired.
- the strategy proposed herein leverages a solid-state additive metal deposition process with which the surface temperatures at the interface of the electrical component do not reach a threshold which cause catastrophic damage to this underlying component.
- the disclosed deposition process does not rely on a planar substrate with which to deposit onto, as is the case for many metal additive processes, including but not limited to powder bed fusion and binder jet printing.
- the process yields mechanical properties akin or superior to the parent structure both because of the strategy of the inherent metal deposition process and because of the process’ ability to leverage dissimilar materials than the parent material. These dissimilar materials can be tailored to meet the requirements of the parent component and the integrated electrical component at specific points along the shape.
- the embedded components may include cables, electrical circuits, sensors, and leads to transfer data from point of interest along a structure to the end-user so that the end-user may interpret and act upon said data.
- the components will additionally include the sensing components which supply the data being transferred.
- These components may include (but are not limited to) fiber optic cables, strain/load cells, pressure gauges, thermocouples, flow meters, counters/encoders, optic sensors, peripheral components, and their various interconnections and shall measure relevant data at specific locations along a structure.
- the components may also describe power supply componentry, which shall transfer and/or boost signal to/from end-user and power sensing capabilities.
- These components include (but are not limited to) solid state batteries, Direct Current or Alternating Current power supplies (such as AC/DC or boost/buck converters) and inductive wires. Active control capabilities will allow these components to react and adapt to conditions and to allow the end-user to optimize functionality in real-time, based on passive data acquired from the sensing capabilities disclosed above.
- an apparatus 300 is provided, as illustrated by Fig. 3.
- the apparatus 300 comprises a first tubular structure 302 comprising a first tubular interface 316 with a first plurality of threads 310, 312 configured to detachably couple with a second plurality of threads 306, 309 of a second tubular interface 318 of a second tubular structure 304.
- the first tubular interface 316 comprises a first set of signal or power transferring path structures 314 formed along one or more of the first plurality of threads 310, 312.
- the apparatus 300 comprises the second tubular structure 304 comprising a second set of signal or power transferring path structures 308 formed along one or more of the second plurality of threads 306, 309.
- the electrical connection pathway may connect a first transmission path 804 and to a second transmission path 806 at an interface 808 so that power and data may be transferred along the first transmission path 804, the second transmission path 806, the interface 808, as illustrated by Fig. 8.
- the electrical connection pathway may connect to a first transmission path 1502 and a second transmission path 1506 at an interface 1504 so that power and data may be transferred along the first transmission path 1502, the second transmission path 1506, the interface 1504, and the electrical connection pathway, as illustrated by Fig. 15.
- the electrical connection pathway may connect to a first transmission path 1402 of the first tubular interface 316 and a second transmission path 1404 of the second tubular interface 318 so that power and data may be transferred along the first transmission path 1402, the second transmission path 1404, and the electrical connection pathway, as illustrated by Fig. 14.
- the first set of signal or power transferring path structures 314 comprises one or more signal or power transferring spring structures 602, 604, 606, 608 of Fig.6 configured to make electrical contact with the second set of signal or power transferring path structures 314.
- the first plurality of threads 310, 312 comprises a first set of threads 310 having a first diameter and a seconds set of threads 312 having a second diameter larger than the first diameter.
- the first tubular structure 302 comprises a conduit 322 formed along a length of the first tubular structure 302.
- the conduit 322 is formed to receive a material, such as a transmission path (e.g., a wire, a conductive material, etc.).
- the first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the material, such as a transmission path 804 or transmission path 806, to the first set of signal or power transferring path structures 314.
- the electromechanical connector interface 808 connects to the first set of signal or power transferring path structures 314 according to an axial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures 314 and the second set of signal or power transferring path structures 308 engaging at a threaded connection between the first tubular interface 316 and the second tubular interface 318 based upon surfaces of the signal or power transferring material abutting at the threaded connection.
- the electromechanical connector interface 808 connects to the first set of signal or power transferring path structures 314 according to a radial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures 314 and the second set of signal or power transferring path structures 308 engaging at a threaded connection between the first tubular interface 316 and the second tubular interface 318 based upon the signal or power transferring material sliding over one another at the threaded connection.
- the first tubular structure 302 comprises an outside surface 914 and the second tubular structure 304 comprises an outside surface 912 where signal or power transfer paths 910 may be located, as illustrated by Figs. 9.
- the apparatus 300 comprises the first tubular interface 316 including the first set of signal or power transferring path structures 314.
- the first tubular structure 302 comprises the conduit 322 formed along a length of the first tubular structure 302 and configured to receive a signal or power transferring material (e.g., a transmission path, such as transmission paths 500, 804, 806, 1404, 1402, 1502, 1506).
- the first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the signal or power transferring material (e.g., the transmission path such as transmission paths 500, 804, 806, 1404, 1402, 1502, 1506) to the first set of signal or power transferring path structures 314.
- the apparatus comprises a second tubular structure 304 comprising a second tubular interface 318 including a second set of signal or power transferring path structures 308.
- a second tubular structure 304 comprising a second tubular interface 318 including a second set of signal or power transferring path structures 308.
- Contact of the second set of signal or power transferring path structures 308 with the first set of signal or power transferring path structures 314 forms an electrical connection pathway with the signal or power transferring material when the first tubular interface 316 is attached to the second tubular interface 318.
- the conduit 322 is positioned within an inner diameter of the first tubular structure 302.
- the conduit 322 comprises an external conduit formed along an outside surface 914 of the first tubular structure 302.
- the conduit 322 is formed within a wall thickness of a wall of the first tubular structure 302.
- the conduit 322 is covered by a closeout structure 320 and is joined to the first tubular structure 302. [079] In some embodiments, the conduit 322 is formed within a recess of the closeout structure 320. [080] In some embodiments, the conduit 322 is formed within a recess of the wall of the first tubular structure 302. [081] In some embodiments, the apparatus 300 comprises a first tubular structure 302 comprising a first tubular interface 316 including a first set of signal or power transferring path structures 314.
- the first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the first transmission path 804 within a conduit 322 of the first tubular structure 302 to the first set of signal or power transferring path structures 314.
- the apparatus 300 comprises a second tubular structure 304 comprising a second transmission path 806 and a second tubular interface 318 including a second set of signal or power transferring path structures 308 connected to the second transmission path 806.
- Contact of the second set of signal or power transferring path structures 308 with the first set of signal or power transferring path structures 314 forms a data communication pathway between the first transmission path 804 and the second transmission path 806.
- the second tubular structure 304 comprises a conduit 332 within which a transmission path may be placed.
- a close out structure may be formed over the conduit 332 to encase and/or seal the transmission path (e.g., a wire).
- the second tubular structure 304 comprises a second conduit 326 within which circuitry 328 may be formed.
- a second closeout structure 324 may be formed over the second conduit 337 to encase and/or seal the circuitry 328 (e.g., sensors, power and signal conditional modules, a router module, a sensor module, a battery module, etc.).
- At least one of the first transmission path 804 or the second transmission path 806 is connected to a sensor 102, illustrated by Fig.1, configured to collect and transmit sensor data over at least one of the first transmission path 804 or the second transmission path 806.
- at least one of the first transmission path 804 or the second transmission path 806 is connected to a computing device 112 configured to at least one of store data received over the first transmission path 804 and the second transmission path 806 or transmit the data over a network to a remote computing device 114, as illustrated by Fig. 1.
- the sensor data is displayed through a graphical user interface 202 on a computing device 200, as illustrated by Fig.2. [085] Fig.
- FIG. 16 illustrates a method 1600 for forming a closeout structure.
- operation 1602 performing a material removal or displacement process to remove or displace material along a wall 1901 of a tubular structure 1902 (e.g., first tubular structure 302 or second tubular structure 304) to create a recessed groove 1904 within the wall 1901 of the tubular structure 1902, as illustrated by Fig. 19.
- a structure 1906 is inserted into the recessed groove 1904 of the tubular structure 1902.
- the structure 1906 comprises at least one of a signal or power transferring structure (e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.).
- a signal or power transferring structure e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.
- the structure is connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 1902.
- the electromechanical connector interface 808 is coupled to a set of path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308) formed along one or more threads of a plurality of threads (e.g., first plurality of threads 310, 312 or a second plurality of threads 306, 309) of the tubular interface.
- a closeout structure 320 is formed over the recessed groove 1904 to create a conduit 322 within which the structure 1906 is positioned.
- a blasting process is performed to project particles at a surface of the wall 1901 of the tubular structure 1902 to create a specified surface finish on the surface of the wall 1901 for subsequent processing.
- the forming of the closeout structure 320 comprises protecting the signal or power transferring structure 1906 with a sheathing before joining of the closeout structure 320 to the tubular structure 1902.
- the forming the closeout structure 320 comprises protecting signal or power transferring structure 1906 with a sheathing during the joining of the closeout structure 320 to the tubular structure 1902.
- the forming the closeout structure 320 comprises performing a cold gas dynamic spray process as the material additive process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902. [090] In some embodiments, the forming the closeout structure 320 comprises performing a thermal spray process as the material additive process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902. [091] In some embodiments, the forming the closeout structure 320 comprises performing a traditional high heat input welding process to seal the closeout structure 320 to the wall 1901 of the tubular structure 1902 to form the conduit 322.
- the forming the closeout structure 320 comprises incorporating a sacrificial structural jig or form into the closeout structure 320 to inhibit warpage of the tubular structure 1902 and closeout structure 320 during a process performed during formation of the closeout structure 320.
- the sacrificial structural jig or form is removed after formation of the closeout structure 320.
- the forming the closeout structure 320 comprises performing an ultrasonic weld process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902.
- the forming the closeout structure 320 comprises creating a closeout lid with a buffer material on the edges that shall be joined to the tubular structure 1902.
- a laser weld process is performed to seal the closeout structure 320 to the wall 1901 of the tubular structure 1902 to form the conduit 322.
- a finishing process is performed to remove excess material resulting from the formation of the closeout structure 320.
- Fig. 17 illustrates a method 1700 for forming a closeout structure.
- a drilling process may be performed to remove material from a wall 1901 of a tubular structure 1902 to create a conduit 322 embedded within the wall 1901 of the tubular structure 1902.
- a signal or power transferring structure 1906 (e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.) may be inserted into the conduit 322 within the tubular structure 1902.
- the signal or power transferring structure 1906 is embedded into the wall 1901 of the tubular structure 1902.
- the signal or power transferring structure 1906 may be connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 1902.
- the electromechanical connector interface 808 is electrically coupled to a set of signal or power transferring path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308).
- the inserting the signal or power transferring structure comprises performing a closed cavity insertion process to insert the signal or power transferring structure 1906 into the conduit 322.
- the drilling process comprises an electrical discharge machining (EDM) drilling process.
- Fig. 18 illustrates a method 1800 for forming a closeout structure.
- a material removal or displacement process to remove or displace material along a wall 2001 of a tubular structure 2002 to create a recessed groove 1904 within the wall 2001 of the tubular structure 2002.
- a closeout structure 320 is formed within the recessed groove 2004 and a conduit 322 is formed within closeout structure 320.
- a signal or power transferring structure 2006 e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.
- a closed cavity insertion process is inserted into the conduit 322 of the closeout structure 320 using a closed cavity insertion process.
- the signal or power transferring structure 2006 is connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 2002.
- the electromechanical connector interface 808 is electrically coupled to a set of signal or power transferring path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308) formed along one or more threads of a plurality of threads (e.g., first plurality of threads 310, 312 or a second plurality of threads 306, 309) of the tubular interface.
- the tubular structure 2002 with the closeout structure 320 attached is heat treated and then a closed cavity insertion process is performed to insert the signal or power transferring structure 2006 into the conduit 322.
- the inserting of the signal or power transferring structure 2006 comprises forming a sacrificial structure of material onto the tubular structure 2002 that will serve as the conduit 322, and forming the closeout structure 320 to the wall of the tubular structure 2002 over the sacrificial structure.
- the inserting of the signal or power transferring structure 2006 comprises chemically or mechanically removing the sacrificial structure of material that will serve as the conduit 322, and performing a closed cavity insertion process to insert the signal or power transferring structure 2006 into the conduit.
- the closeout structure 320 is formed to the wall 2001 of the tubular structure 2002 (e.g., using welding materials 2010, 2012) to form the conduit 322, and a closed cavity insertion process is performed to insert the signal or power transferring structure 2006 into the conduit 322.
- the inserting of the signal or power transferring structure 2006 comprises attaching the signal or power transferring structure 2006 to a dummy structure within the conduit 322, and pulling the dummy structure out of the conduit 322 to pull the signal or power transferring structure 2006 into the conduit 322.
- Fig. 21 illustrates an example of a tubular structure comprising a wall 2108, a first top surface 2106, and a second top surface 2104.
- a signal or power transferring spring structure 608 may be formed within a cavity in the tubular structure.
- a closeout structure 320 may be formed around the signal or power transferring spring structure 608.
- Fig. 22 illustrates an example of a tubular structure comprising a wall 2202 and a first top surface 2210.
- a signal or power transferring spring structure 608 may be formed within a cavity in the tubular structure.
- a closeout structure 320 may be formed around the signal or power transferring spring structure 608.
- the closeout structure 320 may be formed of multiple layers of material, such as a first layer 2208 of a first material and a second layer 2204 of a second material.
- an electromechanical connection may be provided at a threaded tubular interface.
- the insulation material choice of both the box and pin side insulation may be selected based upon material properties which include coefficient of thermal expansion, maximum temperature, strength, and of course electrical conductivity. In some embodiments, various Garolite grades and PEEK may be utilized.
- the insulation on the male pin side incorporates two torque "flats" 714 that are 180 degrees from each other in which a flat is recessed into the tubular in order to provide a counter torque measure to any rotational forces induced on the insulation. If the insulation were to rotate, the soldered connections that run along the axial length of the pipe would be damaged.
- the torque flats can also be accompanied by "teeth that protrude into slots in the axial face of the pin towards the upset. This is another feature option to lock the insulation into place, radially.
- the pin side insulation is locked into place axially due to its placement into a slight recessed groove within the pin. It is further supported when the component is threaded into place since the box further prevents the component from moving in the axial direction.
- the mating surface of the tubular design is recessed into the pin slightly. This means the design cannot be “slipped” over the threads, due to it being a smaller diameter.
- a two-piece design for the male insulation was chosen in which a steel pin 716 holds the two pieces in place, and a kevlar wrap (or other high strength band) 717 can be incorporated in a groove on each end of the insulation to keep in place.
- the torque flats again, promote this placement alignment.
- a high temperature epoxy may be applied under each of these halves to add redundancy to the security of their placement.
- the insulation on the box side is seamless and slips into the cavity of the box. It can be locked in radially using the teeth approach described above for the male insulation in which teeth or pins lock axially into the insulation and fit into slots on the axial face of the box.
- a high temperature epoxy may also be used to keep the insulation in place.
- Torque flats may also be leveraged in the same way as on the pin side, if the flats extend beyond the surface of the box so that the insulation can be slipped into place without catching on any surfaces in the process of assembly. These torque flats should be a quarter turn offset from the torque flats of the pin to mitigate weak points due to these features.
- a final method to lock the box's insulation in place is to machine in slots in the axial direction in which the insulation has a mirrored feature that will slide into the slot, similar to a key in a slot. The insulation on the box side is locked in axially once threaded in place. It is locked in, axially, before threading by an epoxy. [0108] Referring to Figs.
- a trench or groove 2401 is made length-wise into the outer surface of a metallic pipe, such as an oil and gas well casing by subtractive manufacturing techniques, extrusion, or additive build-up of material 2402.
- This ‘wire’ can be fabricated using solid-state coating, or other deposition methods, by coating the trench floor and the sides with an electrical insulator 2403 such- as PEEK, ABS or PLA.
- a conductive path or paths 2404, 2405 are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals.
- the above method may be repeated in order to create discrete conductors separated by insulative layers.
- a thin layer of insulation 2403 is then deposited atop the final conductor 2404 to electrically isolate it; an additional layer of insulation 2408 can be added for added strength and/or protection during the closeout operation (detailed later).
- the ‘closeout operation’ replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded, hermetically sealing, and mechanically joining the underlying material to the parent body. It involves closing out 2406 the wired grooves with solid-state coating, laser powder deposition, ultrasonic welding, or other metallic joining techniques, and may be finished by common turning and/or machining techniques to achieve a ‘seamless’ cylindrical surface.
- cross sections of the conductor 2415 shall be left exposed, and elsewhere an insulative layer 2410 deposited over the metallic casing at the mating surfaces in order to electrically isolate the pipe from the conductive traces (2411, 2412, 2413, 2414) to be laid later.
- the processes detailed above should be used in the flanged section of well-casing couplings 2415 as well, as to create a large surface area of unique conductance (2411, 2412, 2413, 2414) at the ends of casings and inside couplings to transmit signals between casings and couplings 2407 by depositing electrical traces via cold spray, laser powder deposition, ultrasonic welding, or other metallic additive manufacturing techniques.
- tubing or pipe sections having been insulated previously 2410, shall coaxially continue the conductive paths created along their lengths by creating unique conductance paths (or traces) that are layered concentrically spaced from one another (2411, 2412), or positioned at the same radial location, but separated with insulated spaces (2413, 2414).
- a trench or groove 2508 is made length-wise into the outer surface of a metallic pipe, such as an oil and gas well casing 2501, by subtractive manufacturing techniques.
- An electrical conductor 2504 surrounded by an electrical insulator 2503, much like a ‘wire’, is inserted into this groove.
- This ‘wire’ can be fabricated using cold-spray, or other deposition methods, by coating the trench floor and part-way up the sides with an electrical insulator 2503 such-as PEEK, ABS or PLA.
- an electrical insulator 2503 such-as PEEK, ABS or PLA.
- a conductive path or paths are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals.
- the above method may be repeated in order to create discrete conductors separated by insulative layers.
- a thin layer of insulation 2503 is then deposited atop the final conductor 2509 to electrically isolate it; an additional layer of insulation 2505 can be added for added strength and/or protection during the closeout operation (detailed later).
- an additional layer of insulation 2505 can be added for added strength and/or protection during the closeout operation (detailed later).
- a thin sheet of a metal 2506, such as aluminum, stainless steel, or steel is advisable to protect the conductive wire during, and aid in deposition during, the close out operation.
- the ‘closeout operation’ essentially replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded.
- a method includes performing a material removal or displacement process to remove or displace material in the surface of a metal structure to create a recessed area wherein electronic components can be placed within the recessed area.
- the method also includes hermetically sealing the recessed area by cold spraying a metal or a combination of metal filled thermoplastic or thermoset polymer resin with sold spray metal.
- the claimed subject matter is implemented as a method, apparatus, or article of manufacture using standard application or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed subject matter.
- article of manufacture as used herein is intended to encompass a computer application accessible from any computer-readable device, carrier, or media.
- many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter.
- the terms "component”, “module,” “system”, “interface”, and the like are generally intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution.
- a component includes a process running on a processor, a processor, an object, an executable, a thread of execution, an application, or a computer.
- an application running on a controller and the controller can be a component.
- One or more components residing within a process or thread of execution and a component may be localized on one computer or distributed between two or more computers.
- "exemplary" is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous.
- "or” is intended to mean an inclusive “or” rather than an exclusive “or”.
- a first set of information and a second set of information generally correspond to set of information A and set of information B or two different or two identical sets of information or the same set of information.
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Abstract
Techniques are provided for downhole power and data transfer. An apparatus comprises a first tubular structure comprising a first tubular interface with a first plurality of threads configured to detachably couple with a second plurality of threads of a second tubular interface of a second tubular structure. The first tubular interface comprises a first set of signal or power transferring path structures formed along the first plurality of threads. A second tubular structure comprises a second set of signal or power transferring path structures formed along the second plurality of threads. Contact of the second set of signal or power transferring path structures with the first set of signal or power transferring path structures forms an electrical connection pathway when the first tubular interface is attached to the second tubular interface by the first plurality of threads being threaded into the second plurality of threads.
Description
DOWNHOLE POWER AND DATA TRANSFER RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application, titled “DOWNHOLE POWER AND DATA TRANSFER”, filed on October 28th, 2020 and accorded Application No.: 63/106,796, which is incorporated herein by reference. BACKGROUND [001] Currently, especially within the oil and gas industry, it is costly and time consuming to acquire and transmit data from the depths of a well to the surface. Most electronics cannot survive unprotected in the abrasive, corrosive, hot, saline rich, high pressure environment experienced in a well. Few technologies can tolerate this environment and transfer sufficient data to inform the drilling team’s decisions. The difficulty and impracticality of creating physical connections of conductors between these highly stressed threaded components have yet to be achieved at a reasonable scale. DESCRIPTION OF THE DRAWINGS [002] Fig. 1 is an illustration of a block diagram illustrating an example of facilitating communication between a computing device and a remote computing device. [003] Fig. 2 is an illustration of a block diagram illustrating an example of a user interface. [004] Fig. 3 is an illustration of a block diagram of an apparatus for power and data transfer. [005] Fig. 4 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [006] Fig. 5 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [007] Fig. 6 is an illustration of a block diagram of a side view of an apparatus for power and data transfer.
[008] Fig. 7 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [009] Fig. 8 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [010] Fig. 9 is an illustration of a block diagram of an apparatus for power and data transfer. [011] Fig. 10 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals. [012] Fig. 11 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals. [013] Fig. 12 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals. [014] Fig. 13 is an illustration of a block diagram of an apparatus for power and data transfer with one or more inner elastomeric seals. [015] Fig. 14 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [016] Fig. 15 is an illustration of a block diagram of a side view of an apparatus for power and data transfer. [017] Fig. 16 is an illustration of a method for creating a closeout structure. [018] Fig. 17 is an illustration of a method for creating a closeout structure. [019] Fig. 18 is an illustration of a method for creating a closeout structure. [020] Fig. 19 is an illustration of a side view of a closeout structure. [021] Fig. 20 is an illustration of a side view of a closeout structure. [022] Fig. 21 is an illustration of a side view of a closeout structure. [023] Fig. 22 is an illustration of a side view of a closeout structure. [024] Figs. 23A – 23J are illustrations of closeout structure during various stages of creation. [025] Figs. 24A – 24G are illustrations of a smeared conductor. [026] Figs. 25A – 25F are illustrations of a treaded conductor. DETAILED DESCRIPTION
[027] Some examples of the claimed subject matter are now described with reference to the drawings, where like reference numerals are generally used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide an understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced without these specific details. Nothing in this detailed description is admitted as prior art. [028] Transferring signals (power and data) between tools and sensors in downhole fracking wells is a very expensive and difficult task due to the difficulty of transferring signals between metallic casings and couplings. Embedded physical connections are designed to facilitate the continuous and real-time transfer of signals (power and data) between operators and tools in downhole fracking wells. This is done by creating various low impact features that allow a system capable of supporting multiple power and signal conduits to be utilized. Connecting and disconnecting threaded casings in the demanding environments of oil and gas drill sites may prevent physical electrical connections or external conduits from being adhered or mechanically mounted to the surface of a component. For these use cases and more, an embedded physical connection enables signals to be carried from a harsh environment to a data acquisition point. [029] Currently, especially within the oil and gas industry, it is costly and time consuming to acquire and transmit data from the depths of a well to the surface. Most electronics cannot survive unprotected in the abrasive, corrosive, hot, saline rich, high pressure environment experienced in a well. Few technologies can tolerate this environment and transfer sufficient data to inform the drilling team’s decisions. The difficulty and impracticality of creating physical connections of conductors between these highly stressed threaded components have yet to be achieved at a reasonable scale. [030] Because of the aforementioned, there only a few ways to collect data from downhole. One method is the use of mud pulse telemetry where pressure fluctuations are transferred through the mud from downhole to the surface and read as a signal. The large number of noise sources and high signal loss has limited data transmission bandwidth to about 2 bits/hour. The infrequency of data transfer leads to delays in operations wherein
certain decisions require the data to be made. Furthermore, only data is transferred through this method and power is not. [031] Another method includes the use of wireline services, where a conductor is lowered into the well with tools physically connected to it. The problem with using this wireline service is that it can only allow for real-time data transfer at finite intervals, as the wireline is not a permanent or long-standing installation of the well. Furthermore, the use of the wireline is economically limiting as it is an expensive and time-consuming addition to the well creation process. [032] Similarly, fiber optic cables can be used directly by acting as continuous sensors and by delivering the data to the surface. The armored cables are deployed like wireline, where they are unspooled and clamped to the casing string as it is assembled and lowered into the well. The adoption of fiber optics is limited due to being the most expensive data acquisition technique available in the oil industry as well as requiring separate crews to install them. Furthermore, fiber optics work best as continuous strands and any connection points between the two cables will significantly degrade the obtainable signal. Lastly, fiber optic cables are a temporary data acquisition technique as the cable cannot be left in the well for continuous data reading. While acquiring data for a finite interval has some benefits, it would be ideal to have continuous, long-term monitoring of downhole assets and environments. [033] Finally, another data collection method is through utilizing a sensor on a tool itself that logs information to a memory or hard drive device. Once the tool is pulled out of the well and back to surface, the data is then downloaded and read at that time. The issue with this technique is that it does not provide real-time information which is key to making decisions during the operation of the tool that could lead to significant cost- savings of the entire job. [034] Accordingly, as provided herein, a very high area to length aspect ratio isolated cavity is provided in such a way that the strength of the original object (e.g., a tubular structure) is not significantly altered. This cavity will also deform with the original object, allowing utilization in extreme environments. This cavity does not require high aspect drilling operations. This cavity is completely sealed and protected from the environment. This cavity can be populated with a large variety of components.
Such a cavity has the effective final isolated voluminous geometry as would be present had two pipes been used, the exception being one has been created to be small enough to live within the wall of another. Maintaining the properties of the larger tube is crucial, as the oil and gas industry required extreme forces to be transferred with such tubes. The materials and geometries selected for these operations are often designed to be as close to failing as possible to reduce costs and increase performance. The structural performance margins on such a design are so small that the design of such a pocket is specialized and sophisticated enough to minimally impact this performance. The means of creating such a volume must be sufficiently inexpensive and predictable such that the added cost of including the volume is not too great. Once such an isolated volume has been created, many new opportunities present themselves. It is possible to add components to this volume during assembly so that the final system is complete after a joining process has been implemented. [035] For joining processes that require additional heat treat operations that may be too harsh for certain components, another procedure has been implemented. Very high aspect ratio components may be added to a high area to length aspect ratio cavity with specialized procedures. Wires are such a critically important feature that can have a large number of highly valuable goals. These procedures allow the addition of any number of conductors to a long, slim cavity. This procedure consists of using a rigid, slender beam to first pass through the volume, which is then used to pull the conductors through after. This allows the installation of heat sensitive components into an assembly that can otherwise be heat treated or welded. This manufacturing flexibility allows for additional joining processes to be used to create the cavities. These two technologies build off of one another for various use cases, but are robust and valuable enough to exist on their own. Additionally, a high area to length aspect ratio cavity may be used as a conduit to pass fluids with sufficient flow to power equipment. [036] The architecture of a traditional drill string uses many fixed length casings attached with threaded connections. As provided herein, a geometric configuration is provided that allows a radially slim annular volume to exist in a threaded connection without significantly changing the design or increasing critical profile dimensions. This volume can be created by very simple changes to the dimensions of existing features.
This simplicity maintains the original design intents of a complex threaded and even sealed interface. This simplicity drives also costs down significantly, which is a very important consideration when these features need to be so numerous. Such a volume can be located in a threaded connection at locations allowing highly precise alignment with as much clearance as desired. This volume can also be located in regions less susceptible to damage when the casings are being fit up and threaded together. [037] This volume has allowed for the establishment of a robust electromechanical connection across sophisticated threaded connections without significantly increasing the overall profile while maintaining existing operational procedures. We have created an electromechanical connection that is capable of high power transfer, high reliability, high tolerance to debris and greases, operating under extreme deformation, and a high resistance to corrosion. Electrical contacts intended to survive this environment and maintain robust performance must be carefully selected. Most contacts cannot tolerate such harsh conditions. Specific electrical contacts have been selected that can tolerate the debris, forces, shock and even several failures while maintaining a robust and negligibly lossy connection. In some embodiments, the contacts consist of canted springs set into individually insulated grooves to maintain axial spacing for electrical performance and to provide the forces necessary to allow the springs to be compressed into place. The canted springs create a large number of high pressure contact points. The canted springs only require a few loops to remain geometrically stable. A design with sufficient conductors on either side of a canted spring allows an assembled spring to tolerate breakage in numerous locations to maintain very good contact. Additionally, the high contact pressure of a canted spring is capable of pushing through extremely viscous medium and thick oxide layers. [038] A connection is provided that is capable of fitting within a radially slim annular volume. The electrical connection is completed when the connection is threaded together and any and all electrical contacts are axially aligned. Such a connection architecture creates as many independent conductive paths as desired. This lower cost allows the inclusion of multiple independent conductors, a key feature for increasing reliability and bandwidth. The design of this connection allows assembly onto an O-ring style groove to decrease radial dimension. A means to attach wires to electromechanical
connector contacts with minimal geometric dimensions is also provided. This connection is of operating during severe bending and loading of the base pipes, a key feature of anything that expects to operate in such an environment. The temperatures present also have a drastic effect on what a final design is constructed of such that the system being capable of operation across the entire temperature range. [039] A procedure is provided that incorporates specific geometrical features and traditionally utilized processes to create a small volume passage through transitions in a threaded pipe system. This pathway allows a connection from a very high area to length aspect ratio cavities to geometric configurations that allow a radially slim annular volume to exist in a threaded connection. This pathway gives enough flexibility to specific components to highly specific connections. The specific needs of each component segment may differ, so a means to allow multiple segments to connect and function together may be provider. Several features of both the existing connections and the augmented geometries were adapted to work with one another allows the use of manufacturing techniques to complete our design. Extending a closeout lid (e.g., a closeout structure) into the externally upset section of a threaded connection does more than lower the stress on the closeout lid under loading. This transition also creates a thicker lid segment, allowing the passage to vary in height and radius. This increase provides the necessary angle to make a traditional drill process possible. [040] A closeout process is provided that can be used in close proximity to heat sensitive components such as electronics and with components that undergo significant deformation in service. This procedure allows a base material made of a casing-optimal material to be used with a material that maintains excellent elasticity and strength after welding and without the need for heat treatment. The resulting closeout structure is extremely resilient and can deform along with the base material. Such a design is desired when it is impossible to add sensitive components after a heat treatment due to geometric or operational constraints such as the final sealing of a lid designed to protect electronics. The combination of design slightness and performance such that the performance of the component is not significantly affected and the deformation tolerance such that performance envelopes and design architecture is maintained allows such a feature to be incorporated in such an extremely constrained and stressed component. The capability to
create such closeouts that provide hermetic sealing under such conditions without adding significant heat is of high value. Any component to be deployed in this environment may have the strength and toughness of any bonds that may be very close or greater than that of the base material, even with minimal to no heat treatment. This feature provides the ability to maintain existing geometries, even with the addition of larger cavities. [041] A means to accurately detect and orient downhole tools to avoid or align with specific features such as very high area to length aspect ratio isolated cavity is provided. This system prevents perforation operations from penetrating features by providing a system of hardware, sensors and operations to accurately locate such features. Hardware features may already be present in the design, or can be added to a casing. An example of an existing hardware clocking feature would be the insulation surrounding copper wires providing a significantly different eddy current or ultrasonic signature from the surrounding materials. An example of an added clocking feature may be a radioactive tracer providing a radioactive signature that can be found with a directional detector. [042] Traditional electrical wire consists of an electrical conductor surrounded by electrically insulative material. The extension of this is an electrical cable which is a single jacketed line consisting of two or more electrical conductors (wires) separated by insulative material, sometimes each coated with their own insulative jackets. The purpose of the wire is to maintain the continuity of a voltage potential, or the conductive path of electrical current from one electrical component to another. These wires may provide power to, or pass signals between, electrical components and devices without allowing them to affect one another. This general philosophy maintains that electrically conductive materials separated by electrical insulators are able carry distinct signals over some distance in relatively close proximity to one another. [043] A solid-state coating technology is provided that uses high speed particles to plastically deform and deposit them onto a substrate, creating a bond. Using this technology, deposit alternating layers of insulative and conductive materials on top of it, one or more conductive paths (wires) can be created on and/or within various bodies and/or geometries. The solid-state coating technology allows this process to occur in a non-destructive manner requiring only line of sight to the mating surfaces of the pipes,
couplings, or other tubular bodies. A layer of the substrate material can then be used to join the surrounding substrate and closeout the body within which a network of conductors has been embedded allowing for no changes to the surface of a body or its material properties. [044] It is difficult to ensure the relative angular position of an electrical conductor (wire) embedded lengthwise in two sections of interconnecting pipes once threaded into place. The axial distance once fully engaged, however, are fixed in both sections of such a pipe. By extending the conductor coaxially at fixed axial distance along the mating surface of such a pipe section, continuity can be maintained from a conductor in one section of pipe (e.g., a tubular structure) to a conductor in another threaded into it, given the conductors’ exposed cross-sections embedded into each pipe are located at the same axial distance from the pipe center. The female coupling will be extended from the primary threading surface to create an additional electrical connection surface area and volume to house sensing devices, printed circuit boards, batteries, or other components. The electrical connection area will primarily be between the outer surface of the male pipe (e.g., a tubular structure) and the inner surface of the female coupling extension therefore ensuring that the pipe (e.g., a tubular structure) will always maintain intended mechanical performance by never penetrating through critical wall thickness of the pipe. The conductive coaxial trace will establish continuity of an electronic signal at the mating surface between the exposed cross-sections of the embedded wires. [045] A trench or groove is made length-wise into the outer surface of a metallic pipe (e.g., a tubular structure), such as an oil and gas well casing, by subtractive manufacturing techniques. An electrical conductor surrounded by an electrical insulator is inserted into this groove. This electric conductor (e.g., a signal or power transferring structure) may be a wire. This electric conductor can also be fabricated by the following procedure: using cold-spray, or other deposition methods, by coating the trench floor and part-way up the sides with an electrical insulator such-as PEEK, ABS or PLA. Within the electrical insulator, a conductive path or paths (e.g., signal or power transferring path structures) are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals.
[046] The above method may be repeated in order to create discrete conductors separated by insulative layers. A thin layer of insulation is then deposited atop the final conductor to electrically isolate it. An additional layer of insulation can be added for added strength and/or protection during the closeout operation (detailed later). A spring or assembly is inserted into a groove or volume created to ensure the electrical conductor can retract during the threading and assembly process, while also ensuring there is sufficient contact force when the threading and assembly is complete. If necessary, a top the final layer of deposited insulative material, the addition of a thin sheet of a metal, such as aluminum, stainless steel, or steel, is advisable to protect the conductive wire during, and aid in deposition during, the close out operation. The ‘closeout operation’ essentially replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded. It involves closing out the wired grooves with cold spray, laser powder deposition, ultrasonic welding, or other metallic joining techniques, and may be finished by common turning and/or machining techniques to achieve a ‘seamless’ cylindrical surface. Alternatively, this apparatus may be created by utilizing welding techniques to bond a machined lid onto a groove with the geometry necessary to create a volume for equipment. The part can then be heat treated to regain mechanical properties. [047] The inner diameter of the female coupling (e.g., second tubular structure 304) and the male pipe (e.g., a first tubular structure 320) shall expose electrical communication points at varying length-wise positions which correspond to the radial position of the conductor laid in the groove/trench. The radial positioning of each electrical conductor can be planned accordingly to interleave multiple connection points in any given area. [048] At the ends of the casing, cross sections of the conductor shall be left exposed, and elsewhere an insulative layer deposited over the metallic casing at the mating surfaces in order to electrically isolate the pipe from the conductive traces to be laid later. The processes detailed above should be used at all ends of interlocking casings or casings that are to interface with couplings, as to create a large surface area of unique conductance at the ends of casings and inside couplings to transmit signals between casings and couplings by depositing electrical traces via cold spray, laser powder
deposition, ultrasonic welding, or other metallic additive manufacturing techniques. At one of two threaded mating surfaces of adjoining well-casing, tubing or pipe sections, having been insulated previously, shall coaxially continue the conductive paths around the pipe circumference by creating unique conductance paths or traces that are concentric and spaced along the axis from one another. [049] The extension of the female coupling can be used as housing volume to build in any device. Since this material may not affect the integrity or performance of the pipe, the amount of extra volume created by this extension can be used to house external measurement, communication, or other devices. [050] The techniques disclosed herein provide for a permanent installation of data and power transfer capabilities in a well using the existing infrastructure, limiting complexities in implementation and allowing for long-term data acquisition. Furthermore, by embedding the electronic components within the structure of the tool itself, they are better protected from the damaging well environments which may allow for usage of lower cost electronic parts. With the ability to use a wider range of signal transferring components, a higher bandwidth and frequency of signal can be facilitated which likely results in more actionable data at the hands of personnel on the surface. Furthermore, this technology can allow for power to be transferred to tools downhole which can provide greater capabilities and longer lifespan. [051] The solid-state coating technology embedded components are cables, electrical circuits, sensors, and leads which are hermetically integrated and mechanically locked sub-flush into the face of a metal structure such that these electrical components can perform their primary functionalities and be protected within the confines of the parent structure without sacrificing geometric and/or mechanical/structural requirements of the parent structure with which the embedded components are integrated into. [052] It is currently impractical to mount data acquisition and power-based components on an external face of a structure with which harsh environments are presented since this will case high potential for damage and dysfunctionality of said components. Most electronic components and their respective adhesion/mounting strategy cannot survive unprotected in the abrasive, corrosive, hot, saline rich, high
pressure, or turbulent environments experienced at the face of many metal structures. [053] In some embodiments of the presently disclosed techniques, the external metal wall on a surface of a pipe may be built upon by cold spraying (CS) high tensile steel powder to form a cavity that enables electronic components to be placed within that cavity and then sealed by a suitable resin polymer or metal that can then be fully sealed by a secondary CS of metal to that surface to mate the CS wall to the CS surface to form a hermitically seal that can withstand a shearing load that matches, or is superior, to the mechanical properties of the metal pipe. [054] Furthermore, it is currently impractical to integrate these components within the mechanical design of the parent structure due to both the compromising of geometric mating requirements of the existing parent component and of the stringent performance requirements established based on the harsh environments previously alluded to, with which the non-trivial intrusiveness of data and power component integration would cause failure of these criteria. In other words, if an electronic component is to be housed inside or sub-flush of a structural surface, the mechanical integration of the component may be impossible or impractical due to geometric constraints of the parent component based on assembly requirements or environmental limitations. The integration of the electrical component(s) will likely also not be hermetically integrated such that they provide adequate continuity of mechanical properties of the structure. [055] In order to limit intrusiveness of the electrical component integration and to maximize structural qualities relative to environmental requirements, a true embedding approach is required, as provided by the disclosed techniques. With these hermetically integrated components, structural continuity may be accomplished to allow for performance criteria to be met. The caveat to electrical integration in metal structures is that almost all metal forming operations require an extreme amount of heat (typically equating to a temperature above the metal’s melting point) which will cause catastrophic damage to the underlying electrical component. Adaptations in the electrical hardware may be made to account for these extreme heats, but solutions, if possible, require bulky and obtrusive geometries or expensive adaptations that are not practical or cost-effective enough to be implemented. This solid-state coating technology relies on a solid-state
process, meaning it does not melt the added metal material, nor induce temperatures on the parent material/ electrical component that yield significant mechanical damage. Of the few solid-state metallic additive manufacturing processes, it is the most flexible in line-of-site, allowing for complex geometric augmentations without the requirement of a planar substrate surface to apply onto, such as an ultrasonic or friction stir weld adaptation of solid-state additive manufacturing. [056] This solid-state coating technology may use high speed metal particles to plastically deform and deposit them onto a substrate, creating a physical bond. In order to do so efficiently, it is important that the substrate be continuous and allow for a nozzle to remain at an orientation that is as near orthogonal to the substrate as possible at all times during the process. This helps to ensure that adhesion between the coating material and the substrate is robust enough to create a structurally robust hermetic seal that is able to protect components and devices beneath it. Ensuring line-of-sight by constraining chamfer angles, and the radii of fillet curvature it is possible to maintain the ability to spray near-to-normal along a continuous chamfered-filleted-groove in the surface of a metal body. This allows for the high deposition efficiency required for such a close-out operation over a multitude of substrate geometries. Given this surface continuity and ability to maintain normal nozzle attitude with respect to the substrate, it is possible to mechanically join two or more metallic bodies with the CS closeout operation. [057] Referring to Figs. 23A – 23J, the following details a method for safely protecting, hermetically sealing, and mechanically joining electrical circuits, cables, sensors, or other objects into a metal body or substrate 2301 (e.g., a substrate 2301 of a tubular structure), by first creating wide U shaped channel or chamfered filleted-groove 2302 which comprises of a flat base and angled walls by subtractive manufacturing or extrusion, as illustrated by Figs. 23A and 23B. In some embodiments, the angle of this chamfer 2304 is to be no greater than 45 degrees from vertical to allow for line-of sight during the aforementioned closeout operation. Within the bounds of the flat portion of this chamfered-groove, a pocket 2305 is created, by subtractive manufacturing or extrusion, or build-up of additional material to create this profile 2305 via additive manufacturing within which a circuit, sensor, cable, or various object 2306 (e.g., signal or power transferring spring structures and/or signal or power transferring path structures)
which will be housed, as illustrated by Figs.23C – 23E. [058] A positive mold of the pocket/channel 2305 which can be created in a metal, composite, polymer, or ceramic, shall be manufactured as to fill any negative space surrounding the circuit, sensor, cable, or other object 2306 up to the flat area of the filleted-groove 2302. This positive mold 2307 may take many forms, such as a sheet metal box with flanged top filled with insulative material to suspend the object 2306, or metallic, composite, polymer, or ceramic additively manufactured to create the positive mold of the pocket/channel 2305 and negative cutout of the circuit, sensor, cable, or object 2306, as illustrated by Fig. 23F. Whatever the mold, the negative of the object 2306 to be embedded must be created for it to be securely housed. [059] An adhesive, epoxy or other sealant 2308 shall be used to affix the mold and object assembly (2306, 2307), or object 2306 itself if its geometry is amenable to the process, to the pocket and seal any gap between the metal body substrate 2301, and the mold or object itself 2307, as illustrated by Fig. 23G. The addition of a thin sheet of a metal 2309, such as aluminum, stainless steel, steel, or a metal filled thermoplastic or thermoset polymer resin on top of the positive mold for additional protection if desired or necessary during the closeout operation 2310, as illustrated by Figs. 23H – 23J. A closeout (e.g., creation of a closeout structure 302) of the assembly is performed with cold spray using metal, polymer, composite, or ceramic powder deposited over the filleted-groove 2302, designed in such a way that a spray nozzle is able to remain normal to all surfaces during this operation. The cold spray material can be machined to achieve a smooth finish by subtractive manufacturing techniques if desired. [060] While there are several metal augmentation strategies, the strategy proposed herein leverages a solid-state additive metal deposition process with which the surface temperatures at the interface of the electrical component do not reach a threshold which cause catastrophic damage to this underlying component. Furthermore, the disclosed deposition process does not rely on a planar substrate with which to deposit onto, as is the case for many metal additive processes, including but not limited to powder bed fusion and binder jet printing. Additionally, the process yields mechanical properties akin or superior to the parent structure both because of the strategy of the inherent metal
deposition process and because of the process’ ability to leverage dissimilar materials than the parent material. These dissimilar materials can be tailored to meet the requirements of the parent component and the integrated electrical component at specific points along the shape. Due to the solid-state nature of this process, there is virtually no “cool down” times of any melt pools, allowing the operator to deposit large volumes of powder without needing to wait for thermal properties to change. This allows this process to be an optimal solution used in high-volume production scale output. [061] The embedded components may include cables, electrical circuits, sensors, and leads to transfer data from point of interest along a structure to the end-user so that the end-user may interpret and act upon said data. The components will additionally include the sensing components which supply the data being transferred. These components may include (but are not limited to) fiber optic cables, strain/load cells, pressure gauges, thermocouples, flow meters, counters/encoders, optic sensors, peripheral components, and their various interconnections and shall measure relevant data at specific locations along a structure. The components may also describe power supply componentry, which shall transfer and/or boost signal to/from end-user and power sensing capabilities. These components include (but are not limited to) solid state batteries, Direct Current or Alternating Current power supplies (such as AC/DC or boost/buck converters) and inductive wires. Active control capabilities will allow these components to react and adapt to conditions and to allow the end-user to optimize functionality in real-time, based on passive data acquired from the sensing capabilities disclosed above. These components will be used to create a ‘closed-loop’ system with which the passive and active capacity created by embedded components will allow for an input-output cycle between the two to self-optimize based on real-time data. Examples of this include flow directional or magnitude control based on pressures and temperatures, current induction based on external stimuli, reliable and lengthy signal transfer through the boosting of signal via inductive power connections or terminals, geometric mapping and load sensing of a structure through extensive intravenous fiber optic sensors. [062] In some embodiments, an apparatus 300 is provided, as illustrated by Fig. 3. The apparatus 300 comprises a first tubular structure 302 comprising a first tubular interface 316 with a first plurality of threads 310, 312 configured to detachably couple
with a second plurality of threads 306, 309 of a second tubular interface 318 of a second tubular structure 304. The first tubular interface 316 comprises a first set of signal or power transferring path structures 314 formed along one or more of the first plurality of threads 310, 312. The apparatus 300 comprises the second tubular structure 304 comprising a second set of signal or power transferring path structures 308 formed along one or more of the second plurality of threads 306, 309. Contact of the second set of signal or power transferring path structures 308 with the first set of signal or power transferring path structures 314 forms an electrical connection pathway when the first tubular interface 316 is attached to the second tubular interface 318 by the first plurality of threads 310, 312 being threaded into the second plurality of threads 306, 309, as illustrated by Fig. 4. [063] In some embodiments, the electrical connection pathway may connect a first transmission path 804 and to a second transmission path 806 at an interface 808 so that power and data may be transferred along the first transmission path 804, the second transmission path 806, the interface 808, as illustrated by Fig. 8. A transmission path, such as transmission path 500 of Fig. 5, may comprise a material, a wire, conductive material, a signal or power transferring structure, or any other material that may be used for transmitting power and/or data signals. [064] In some embodiments, the electrical connection pathway may connect to a first transmission path 1502 and a second transmission path 1506 at an interface 1504 so that power and data may be transferred along the first transmission path 1502, the second transmission path 1506, the interface 1504, and the electrical connection pathway, as illustrated by Fig. 15. [065] In some embodiments, the electrical connection pathway may connect to a first transmission path 1402 of the first tubular interface 316 and a second transmission path 1404 of the second tubular interface 318 so that power and data may be transferred along the first transmission path 1402, the second transmission path 1404, and the electrical connection pathway, as illustrated by Fig. 14. [066] In some embodiments, the first set of signal or power transferring path structures 314 comprises one or more signal or power transferring spring structures 602,
604, 606, 608 of Fig.6 configured to make electrical contact with the second set of signal or power transferring path structures 314. In some embodiments, the one or more signal or power transferring spring structures 602, 604, 606, 608 of Fig. 6 are configured to make electrical contact one or more signal or power transferring contacts 702, 704, 706, 708 of Fig.7 of the second set of signal or power transferring path structures 314 when the first tubular interface 316 is attached to the second tubular interface 318, as illustrated by Fig. 4. [067] In some embodiments, the first plurality of threads 310, 312 comprises a first set of threads 310 having a first diameter and a seconds set of threads 312 having a second diameter larger than the first diameter. [068] In some embodiments, one or more inner elastomeric seal 1002, 1004, 1006 of Fig. 10, 1102 of Fig. 11, 1202 of Fig. 12, and 1302, 1304 of Fig. 13 may be positioned along the first plurality of threads 310, 312 or the second plurality of threads 309, 306 at an interface between the first set of threads 310 and the second set of threads 312. In some embodiments, the first plurality of threads 310, 312 comprises a duel step straight thread configuration. [069] In some embodiments, the first tubular structure 302 comprises a conduit 322 formed along a length of the first tubular structure 302. The conduit 322 is formed to receive a material, such as a transmission path (e.g., a wire, a conductive material, etc.). [070] In some embodiments, the first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the material, such as a transmission path 804 or transmission path 806, to the first set of signal or power transferring path structures 314. [071] In some embodiments, the electromechanical connector interface 808 connects to the first set of signal or power transferring path structures 314 according to an axial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures 314 and the second set of signal or power transferring path structures 308 engaging at a threaded connection between the first tubular interface 316 and the second tubular interface 318 based upon surfaces of the signal or power transferring material abutting at
the threaded connection. [072] In some embodiments, the electromechanical connector interface 808 connects to the first set of signal or power transferring path structures 314 according to a radial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures 314 and the second set of signal or power transferring path structures 308 engaging at a threaded connection between the first tubular interface 316 and the second tubular interface 318 based upon the signal or power transferring material sliding over one another at the threaded connection. [073] In some embodiments, the first tubular structure 302 comprises an outside surface 914 and the second tubular structure 304 comprises an outside surface 912 where signal or power transfer paths 910 may be located, as illustrated by Figs. 9. [074] In some embodiments, the apparatus 300 comprises the first tubular interface 316 including the first set of signal or power transferring path structures 314. The first tubular structure 302 comprises the conduit 322 formed along a length of the first tubular structure 302 and configured to receive a signal or power transferring material (e.g., a transmission path, such as transmission paths 500, 804, 806, 1404, 1402, 1502, 1506). The first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the signal or power transferring material (e.g., the transmission path such as transmission paths 500, 804, 806, 1404, 1402, 1502, 1506) to the first set of signal or power transferring path structures 314. The apparatus comprises a second tubular structure 304 comprising a second tubular interface 318 including a second set of signal or power transferring path structures 308. Contact of the second set of signal or power transferring path structures 308 with the first set of signal or power transferring path structures 314 forms an electrical connection pathway with the signal or power transferring material when the first tubular interface 316 is attached to the second tubular interface 318. [075] In some embodiments, the conduit 322 is positioned within an inner diameter of the first tubular structure 302. [076] In some embodiments, the conduit 322 comprises an external conduit formed
along an outside surface 914 of the first tubular structure 302. [077] In some embodiments, the conduit 322 is formed within a wall thickness of a wall of the first tubular structure 302. [078] In some embodiments, the conduit 322 is covered by a closeout structure 320 and is joined to the first tubular structure 302. [079] In some embodiments, the conduit 322 is formed within a recess of the closeout structure 320. [080] In some embodiments, the conduit 322 is formed within a recess of the wall of the first tubular structure 302. [081] In some embodiments, the apparatus 300 comprises a first tubular structure 302 comprising a first tubular interface 316 including a first set of signal or power transferring path structures 314. The first tubular structure 302 comprises an electromechanical connector interface 808 configured to electrically connect the first transmission path 804 within a conduit 322 of the first tubular structure 302 to the first set of signal or power transferring path structures 314. The apparatus 300 comprises a second tubular structure 304 comprising a second transmission path 806 and a second tubular interface 318 including a second set of signal or power transferring path structures 308 connected to the second transmission path 806. Contact of the second set of signal or power transferring path structures 308 with the first set of signal or power transferring path structures 314 forms a data communication pathway between the first transmission path 804 and the second transmission path 806. [082] In some embodiments, the second tubular structure 304 comprises a conduit 332 within which a transmission path may be placed. In some embodiments, a close out structure may be formed over the conduit 332 to encase and/or seal the transmission path (e.g., a wire). In some embodiments, the second tubular structure 304 comprises a second conduit 326 within which circuitry 328 may be formed. A second closeout structure 324 may be formed over the second conduit 337 to encase and/or seal the circuitry 328 (e.g., sensors, power and signal conditional modules, a router module, a sensor module, a battery module, etc.).
[083] In some embodiments, at least one of the first transmission path 804 or the second transmission path 806 is connected to a sensor 102, illustrated by Fig.1, configured to collect and transmit sensor data over at least one of the first transmission path 804 or the second transmission path 806. [084] In some embodiments, at least one of the first transmission path 804 or the second transmission path 806 is connected to a computing device 112 configured to at least one of store data received over the first transmission path 804 and the second transmission path 806 or transmit the data over a network to a remote computing device 114, as illustrated by Fig. 1. In some embodiments, the sensor data is displayed through a graphical user interface 202 on a computing device 200, as illustrated by Fig.2. [085] Fig. 16 illustrates a method 1600 for forming a closeout structure. During operation 1602, performing a material removal or displacement process to remove or displace material along a wall 1901 of a tubular structure 1902 (e.g., first tubular structure 302 or second tubular structure 304) to create a recessed groove 1904 within the wall 1901 of the tubular structure 1902, as illustrated by Fig. 19. During operation 1604, a structure 1906 is inserted into the recessed groove 1904 of the tubular structure 1902. The structure 1906 comprises at least one of a signal or power transferring structure (e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.). During operation 1606, the structure is connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 1902. The electromechanical connector interface 808 is coupled to a set of path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308) formed along one or more threads of a plurality of threads (e.g., first plurality of threads 310, 312 or a second plurality of threads 306, 309) of the tubular interface. During operation 1608, a closeout structure 320 is formed over the recessed groove 1904 to create a conduit 322 within which the structure 1906 is positioned. [086] In some embodiments, a blasting process is performed to project particles at a surface of the wall 1901 of the tubular structure 1902 to create a specified surface finish
on the surface of the wall 1901 for subsequent processing. [087] In some embodiments, the forming of the closeout structure 320 comprises protecting the signal or power transferring structure 1906 with a sheathing before joining of the closeout structure 320 to the tubular structure 1902. [088] In some embodiments, the forming the closeout structure 320 comprises protecting signal or power transferring structure 1906 with a sheathing during the joining of the closeout structure 320 to the tubular structure 1902. [089] In some embodiments, the forming the closeout structure 320 comprises performing a cold gas dynamic spray process as the material additive process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902. [090] In some embodiments, the forming the closeout structure 320 comprises performing a thermal spray process as the material additive process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902. [091] In some embodiments, the forming the closeout structure 320 comprises performing a traditional high heat input welding process to seal the closeout structure 320 to the wall 1901 of the tubular structure 1902 to form the conduit 322. [092] In some embodiments, the forming the closeout structure 320 comprises incorporating a sacrificial structural jig or form into the closeout structure 320 to inhibit warpage of the tubular structure 1902 and closeout structure 320 during a process performed during formation of the closeout structure 320. The sacrificial structural jig or form is removed after formation of the closeout structure 320. [093] In some embodiments, the forming the closeout structure 320 comprises performing an ultrasonic weld process to apply material over the recessed groove 1904 to form the conduit 322 and join the closeout structure 320 to the tubular structure 1902. [094] In some embodiments, the forming the closeout structure 320 comprises creating a closeout lid with a buffer material on the edges that shall be joined to the tubular structure 1902. A laser weld process is performed to seal the closeout structure
320 to the wall 1901 of the tubular structure 1902 to form the conduit 322. [095] In some embodiments, a finishing process is performed to remove excess material resulting from the formation of the closeout structure 320. [096] Fig. 17 illustrates a method 1700 for forming a closeout structure. During operation 1702, a drilling process may be performed to remove material from a wall 1901 of a tubular structure 1902 to create a conduit 322 embedded within the wall 1901 of the tubular structure 1902. During operation 1704, a signal or power transferring structure 1906 (e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.) may be inserted into the conduit 322 within the tubular structure 1902. The signal or power transferring structure 1906 is embedded into the wall 1901 of the tubular structure 1902. During operation 1706, the signal or power transferring structure 1906 may be connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 1902. The electromechanical connector interface 808 is electrically coupled to a set of signal or power transferring path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308). [097] In some embodiments, the inserting the signal or power transferring structure comprises performing a closed cavity insertion process to insert the signal or power transferring structure 1906 into the conduit 322. [098] In some embodiments, the drilling process comprises an electrical discharge machining (EDM) drilling process. [099] Fig. 18 illustrates a method 1800 for forming a closeout structure. During operation 1802, a material removal or displacement process to remove or displace material along a wall 2001 of a tubular structure 2002 to create a recessed groove 1904 within the wall 2001 of the tubular structure 2002. During operation 1804, a closeout structure 320 is formed within the recessed groove 2004 and a conduit 322 is formed within closeout structure 320. During operation 1806, a signal or power transferring structure 2006 (e.g., a signal or power transferring spring structure 608; transmission paths 500, 804, 806, 1404, 1402, 1502, 1506; a wire; etc.) is inserted into the conduit 322
of the closeout structure 320 using a closed cavity insertion process. During operation 1808, the signal or power transferring structure 2006 is connected to an electromechanical connector interface 808 of a tubular interface (e.g., first tubular interface 316 or second tubular interface 318) of the tubular structure 2002. The electromechanical connector interface 808 is electrically coupled to a set of signal or power transferring path structures (e.g., first set of signal or power transferring path structures 314 or second set of signal or power transferring path structures 308) formed along one or more threads of a plurality of threads (e.g., first plurality of threads 310, 312 or a second plurality of threads 306, 309) of the tubular interface. [0100] In some embodiments, the tubular structure 2002 with the closeout structure 320 attached is heat treated and then a closed cavity insertion process is performed to insert the signal or power transferring structure 2006 into the conduit 322. [0101] In some embodiments, the inserting of the signal or power transferring structure 2006 comprises forming a sacrificial structure of material onto the tubular structure 2002 that will serve as the conduit 322, and forming the closeout structure 320 to the wall of the tubular structure 2002 over the sacrificial structure. In some embodiments, the inserting of the signal or power transferring structure 2006 comprises chemically or mechanically removing the sacrificial structure of material that will serve as the conduit 322, and performing a closed cavity insertion process to insert the signal or power transferring structure 2006 into the conduit. [0102] In some embodiments, the closeout structure 320 is formed to the wall 2001 of the tubular structure 2002 (e.g., using welding materials 2010, 2012) to form the conduit 322, and a closed cavity insertion process is performed to insert the signal or power transferring structure 2006 into the conduit 322. [0103] In some embodiments, the inserting of the signal or power transferring structure 2006 comprises attaching the signal or power transferring structure 2006 to a dummy structure within the conduit 322, and pulling the dummy structure out of the conduit 322 to pull the signal or power transferring structure 2006 into the conduit 322. [0104] Fig. 21 illustrates an example of a tubular structure comprising a wall 2108, a first top surface 2106, and a second top surface 2104. A signal or power transferring
spring structure 608 may be formed within a cavity in the tubular structure. A closeout structure 320 may be formed around the signal or power transferring spring structure 608. [0105] Fig. 22 illustrates an example of a tubular structure comprising a wall 2202 and a first top surface 2210. A signal or power transferring spring structure 608 may be formed within a cavity in the tubular structure. A closeout structure 320 may be formed around the signal or power transferring spring structure 608. The closeout structure 320 may be formed of multiple layers of material, such as a first layer 2208 of a first material and a second layer 2204 of a second material. [0106] Referring back to Fig. 7, an electromechanical connection may be provided at a threaded tubular interface. This provides the ability fit in a radially slim volume while maximizing robustness and electrical properties. The insulation material choice of both the box and pin side insulation may be selected based upon material properties which include coefficient of thermal expansion, maximum temperature, strength, and of course electrical conductivity. In some embodiments, various Garolite grades and PEEK may be utilized. The insulation on the male pin side incorporates two torque "flats" 714 that are 180 degrees from each other in which a flat is recessed into the tubular in order to provide a counter torque measure to any rotational forces induced on the insulation. If the insulation were to rotate, the soldered connections that run along the axial length of the pipe would be damaged. The torque flats can also be accompanied by "teeth that protrude into slots in the axial face of the pin towards the upset. This is another feature option to lock the insulation into place, radially. The pin side insulation is locked into place axially due to its placement into a slight recessed groove within the pin. It is further supported when the component is threaded into place since the box further prevents the component from moving in the axial direction. To keep the design even more compact radially, the mating surface of the tubular design is recessed into the pin slightly. This means the design cannot be "slipped" over the threads, due to it being a smaller diameter. A two-piece design for the male insulation was chosen in which a steel pin 716 holds the two pieces in place, and a kevlar wrap (or other high strength band) 717 can be incorporated in a groove on each end of the insulation to keep in place. The torque flats, again, promote this placement alignment. A high temperature epoxy may be applied under each of these halves to add redundancy to the security of their placement.
[0107] The insulation on the box side is seamless and slips into the cavity of the box. It can be locked in radially using the teeth approach described above for the male insulation in which teeth or pins lock axially into the insulation and fit into slots on the axial face of the box. A high temperature epoxy may also be used to keep the insulation in place. Torque flats may also be leveraged in the same way as on the pin side, if the flats extend beyond the surface of the box so that the insulation can be slipped into place without catching on any surfaces in the process of assembly. These torque flats should be a quarter turn offset from the torque flats of the pin to mitigate weak points due to these features. A final method to lock the box's insulation in place is to machine in slots in the axial direction in which the insulation has a mirrored feature that will slide into the slot, similar to a key in a slot. The insulation on the box side is locked in axially once threaded in place. It is locked in, axially, before threading by an epoxy. [0108] Referring to Figs. 24A – 24G, a trench or groove 2401 is made length-wise into the outer surface of a metallic pipe, such as an oil and gas well casing by subtractive manufacturing techniques, extrusion, or additive build-up of material 2402. An electrical conductor 2405 surrounded by an electrical insulator 2403, a wire, is inserted into this groove. This ‘wire’ can be fabricated using solid-state coating, or other deposition methods, by coating the trench floor and the sides with an electrical insulator 2403 such- as PEEK, ABS or PLA. Within the electrical insulator, a conductive path or paths 2404, 2405 are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals. [0109] The above method may be repeated in order to create discrete conductors separated by insulative layers. A thin layer of insulation 2403 is then deposited atop the final conductor 2404 to electrically isolate it; an additional layer of insulation 2408 can be added for added strength and/or protection during the closeout operation (detailed later). Atop the final layer of deposited insulative material, the addition of a thin sheet of a metal 2409, such as aluminum, stainless steel, or steel, is advisable to protect the insulated wire during, and aid in deposition during, the close out operation. The ‘closeout operation’ replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded, hermetically sealing, and
mechanically joining the underlying material to the parent body. It involves closing out 2406 the wired grooves with solid-state coating, laser powder deposition, ultrasonic welding, or other metallic joining techniques, and may be finished by common turning and/or machining techniques to achieve a ‘seamless’ cylindrical surface. [0110] At the ends of the casing, cross sections of the conductor 2415 shall be left exposed, and elsewhere an insulative layer 2410 deposited over the metallic casing at the mating surfaces in order to electrically isolate the pipe from the conductive traces (2411, 2412, 2413, 2414) to be laid later. The processes detailed above should be used in the flanged section of well-casing couplings 2415 as well, as to create a large surface area of unique conductance (2411, 2412, 2413, 2414) at the ends of casings and inside couplings to transmit signals between casings and couplings 2407 by depositing electrical traces via cold spray, laser powder deposition, ultrasonic welding, or other metallic additive manufacturing techniques. [0111] At one of two mating surfaces of adjoining well-casing, tubing or pipe sections, having been insulated previously 2410, shall coaxially continue the conductive paths created along their lengths by creating unique conductance paths (or traces) that are layered concentrically spaced from one another (2411, 2412), or positioned at the same radial location, but separated with insulated spaces (2413, 2414). [0112] Referring to Figs. 25A – 25F, a trench or groove 2508 is made length-wise into the outer surface of a metallic pipe, such as an oil and gas well casing 2501, by subtractive manufacturing techniques. An electrical conductor 2504 surrounded by an electrical insulator 2503, much like a ‘wire’, is inserted into this groove. This ‘wire’ can be fabricated using cold-spray, or other deposition methods, by coating the trench floor and part-way up the sides with an electrical insulator 2503 such-as PEEK, ABS or PLA. Within the electrical insulator, a conductive path or paths (2509, 2510, 2511) are created by applying conductive paint, using metallic additive manufacturing to deposit the conductive path, laying down a solid conductive wire, or electroplating the area using conductive materials such as copper, silver, or other metals. [0113] The above method may be repeated in order to create discrete conductors separated by insulative layers. A thin layer of insulation 2503 is then deposited atop the
final conductor 2509 to electrically isolate it; an additional layer of insulation 2505 can be added for added strength and/or protection during the closeout operation (detailed later). Atop the final layer of deposited insulative material, the addition of a thin sheet of a metal 2506, such as aluminum, stainless steel, or steel, is advisable to protect the conductive wire during, and aid in deposition during, the close out operation. The ‘closeout operation’ essentially replaces the material removed in the subtractive process used to cut the groove into which the wires have been embedded. It involves closing out 2507 the wired grooves with cold spray, laser powder deposition, ultrasonic welding, or other metallic joining techniques, and may be finished by common turning and/or machining techniques to achieve a ‘seamless’ cylindrical surface. [0114] The pitch of tapered ends of this pipe and cut-threads shall lead to exposed conductors at varying length-wise positions which correspond to the radial position of the conductor laid in the groove/trench. The radial positioning of each electrical conductor can be planned accordingly to interleave multiple connection points at the threaded interface. [0115] At the ends of the casing, cross sections of the conductor 2515 shall be left exposed, and elsewhere an insulative layer deposited over the metallic casing at the mating surfaces in order to electrically isolate the pipe from the conductive traces (2513, 2514) to be laid later. The processes detailed above should be used at all ends of interlocking casings (2501, 2516) or casings that are to interface with couplings 2502, as to create a large surface area of unique conductance (2513, 2514) at the ends of casings and inside couplings to transmit signals between casings and couplings by depositing electrical traces via cold spray, laser powder deposition, ultrasonic welding, or other metallic additive manufacturing techniques. At one of two threaded mating surfaces of adjoining well-casing, tubing or pipe sections, having been insulated previously, shall coaxially continue the conductive paths 2512 around the pipe circumference by creating unique conductance paths or traces that are concentric and spaced along the axis from one another (2513, 2514). [0116] In some embodiments, a method is provided. The method includes performing a material removal or displacement process to remove or displace material in
the surface of a metal structure to create a recessed area wherein electronic components can be placed within the recessed area. The method also includes hermetically sealing the recessed area by cold spraying a metal or a combination of metal filled thermoplastic or thermoset polymer resin with sold spray metal. [0117] Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing at least some of the claims. [0118] Various operations of embodiments are provided herein. The order in which some or all of the operations are described should not be construed to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated given the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. Also, it will be understood that not all operations are necessary in some embodiments. [0119] Furthermore, the claimed subject matter is implemented as a method, apparatus, or article of manufacture using standard application or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed subject matter. The term "article of manufacture" as used herein is intended to encompass a computer application accessible from any computer-readable device, carrier, or media. Of course, many modifications may be made to this configuration without departing from the scope or spirit of the claimed subject matter. [0120] As used in this application, the terms "component”, "module," "system", "interface", and the like are generally intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component includes a process running on a processor, a processor, an object, an executable, a thread of execution, an application, or a computer. By way of illustration, both an application running on a controller and the controller can be a component. One or more components residing within a process or thread of execution
and a component may be localized on one computer or distributed between two or more computers. [0121] Moreover, "exemplary" is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, "or" is intended to mean an inclusive "or" rather than an exclusive "or". In addition, "a" and "an" as used in this application are generally be construed to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A or B and/or both A and B. Furthermore, to the extent that "includes", "having", "has", "with", or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term "comprising”. [0122] Many modifications may be made to the instant disclosure without departing from the scope or spirit of the claimed subject matter. Unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first set of information and a second set of information generally correspond to set of information A and set of information B or two different or two identical sets of information or the same set of information. [0123] Also, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The disclosure includes all such modifications and alterations and is limited only by the scope of the following claims. In particular regard to the various functions performed by the above described components (e.g., elements, resources, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure. In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be
desired and advantageous for any given or particular application.
Claims
What is claimed is: 1. An apparatus, comprising: a first tubular structure comprising a first tubular interface with a first plurality of threads configured to detachably couple with a second plurality of threads of a second tubular interface of a second tubular structure, wherein the first tubular interface comprises a first set of signal or power transferring path structures formed along one or more of the first plurality of threads; and the second tubular structure comprising a second set of signal or power transferring path structures formed along one or more of the second plurality of threads, wherein contact of the second set of signal or power transferring path structures with the first set of signal or power transferring path structures forms an electrical connection pathway when the first tubular interface is attached to the second tubular interface by the first plurality of threads being threaded into the second plurality of threads.
2. The apparatus of claim 1, wherein the first set of signal or power transferring path structures comprises one or more signal or power transferring spring structures configured to make electrical contact with one or more signal or power transferring contacts of the second set of signal or power transferring path structures when the first tubular interface is attached to the second tubular interface.
3. The apparatus of claim 1, wherein the first plurality of threads comprises a first set of threads having a first diameter and a seconds set of threads having a second diameter larger than the first diameter.
4. The apparatus of claim 3, wherein the first tubular interface comprises an inner elastomeric seal positioned along the first plurality of threads at an interface between the first set of threads and the second set of threads.
5. The apparatus of claim 1, wherein the first plurality of threads comprises a duel step straight thread configuration.
6. The apparatus of claim 1, wherein the first tubular structure comprises: a conduit formed along a length of the first tubular structure, wherein the conduit is formed to receive a material.
7. The apparatus of claim 6, wherein the first tubular interface comprises: an electromechanical connector interface configured to electrically connect the material to the first set of signal or power transferring path structures.
8. The apparatus of claim 7, wherein the electromechanical connector interface connects to the first set of signal or power transferring path structures according to an axial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures and the second set of signal or power transferring path structures engaging at a threaded connection between the first tubular interface and the second tubular interface based upon surfaces of the signal or power transferring material abutting at the threaded connection.
9. The apparatus of claim 7, wherein the electromechanical connector interface connects to the first set of signal or power transferring path structures according to a radial configuration where the electrical connection pathway is created by signal or power transferring materials of the first set of signal or power transferring path structures and the second set of signal or power transferring path structures engaging at a threaded connection between the first tubular interface and the second tubular interface based upon the signal or power transferring material sliding over one another at the threaded connection.
10. An apparatus comprising: a first tubular structure comprising a first tubular interface including a first set of signal or power transferring path structures, wherein the first tubular structure comprises a conduit formed along a length of the first tubular structure and configured to receive a signal or power transferring material , and wherein the first tubular structure comprises an
electromechanical connector interface configured to electrically connect the signal or power transferring material to the first set of signal or power transferring path structures; and a second tubular structure comprising a second tubular interface including a second set of signal or power transferring path structures, wherein contact of the second set of signal or power transferring path structures with the first set of signal or power transferring path structures forms an electrical connection pathway with the signal or power transferring material when the first tubular interface is attached to the second tubular interface.
11. The apparatus of claim 10, wherein the conduit is positioned within an inner diameter of the first tubular structure.
12. The apparatus of claim 10, wherein the conduit comprising an external conduit formed along an outside surface of the first tubular structure.
13. The apparatus of claim 10, wherein the conduit is formed within a wall thickness of a wall of the first tubular structure.
14. The apparatus of claim 13, wherein the conduit is covered by a closeout structure and is joined to the first tubular structure.
15. The apparatus of claim 14, wherein the conduit is formed within a recess of the closeout structure.
16. The apparatus of claim 14, wherein the conduit is formed within a recess of the wall of the first tubular structure.
17. A method comprising:
performing a material removal or displacement process to remove or displace material in the surface of a metal structure to create a recessed area wherein electronic components can be placed within the recessed area; and hermetically sealing the recessed area by cold spraying a metal or a combination of metal filled thermoplastic or thermoset polymer resin with sold spray metal.
18. The method of claim 17, wherein the hermetically sealing comprises: forming a closeout structure over the recessed area.
19. The method of claim 17, comprising: connecting the electronic components to an electromechanical connector interface of a tubular interface of a tubular structure.
20. The method of claim 19, wherein the electromechanical connector interface is coupled to a set of path structures formed along one or more threads of a plurality of threads of the tubular interface.
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US202063106796P | 2020-10-28 | 2020-10-28 | |
US63/106,796 | 2020-10-28 |
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WO2022094144A1 true WO2022094144A1 (en) | 2022-05-05 |
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PCT/US2021/057140 WO2022094144A1 (en) | 2020-10-28 | 2021-10-28 | Downhole power and data transfer |
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Cited By (2)
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EP4446559A1 (en) | 2023-04-11 | 2024-10-16 | Tenaris Connections B.V. | Threaded connection |
EP4446560A1 (en) | 2023-04-11 | 2024-10-16 | Tenaris Connections B.V. | Coupling for a threaded connection |
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