Abstract:
A data transmission system which may be used in any industrial installation in which an A.C. powered device is remotely located and in which it is desired (i) to monitor certain parameters, and/or (ii) to control certain operational functions at the remote site. The power cable used to carry A.C. power to the remotely operating device is also used to carry instrumentation, communication, and control signals from the local control and readout equipment located at the surface to an instrumentation and control package installed at the remote site in the down-hole location. The present invention comprises means for the simultaneous bidirectional transmission of digital data between the local and remote sites by means of a modulated D.C. loop current to thereby accomplish the required monitoring and control functions.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the invention 
     This invention relates to the field of electrical instrumentation and control, and more particularly, to an instrumentation apparatus which enables the sensing of physical parameters and the control of operational functions in a remotely located A.C. powered installation. 
     2. The Prior Art 
     Numerous industrial installations exist in which an A.C. powered motor and pump assembly or other alternating current device is operated at a remote location to which access is difficult, costly and/or impractical, if not impossible. An example of such an installation is the motor and pump assembly of a submersible pumping system operating near the bottom of a subterranean bore-hole (referred to as &#34;down-hole&#34;). In such an installation, there is often a requirement to monitor certain physical parameters present in the down-hole environment, particularly the temperature and pressure therein. Moreover, in such installations, there will also exist the requirement to remotely control certain operational functions such as the flow of fluid through a down-hole solenoid controlled valve. 
     Prior art solutions to the problem of providing a communication link between a locally situated control and monitoring unit and a remotely situated control and instrumentation unit have included the use of the conductors of the 3 φ power supply cable for the transmission of communication signals thereby precluding the need for a separate communication pathway. Examples of such prior art systems are disclosed in U.S. Pat. Nos. 3,284,669, 3,340,500, 4,157,535, 4,178,579, 4,788,545, and 4,803,483 issued to Boyd, Boyd et al., Balkanli, McGibbeny et al., Farque, and Vandervier et al. respectively. Of these prior art systems, Farque and Vandervier et al. both transmit the communication signal over one phase of the 3 φ power supply, Boyd transmits the communication signal over two phases of the 3 φ power supply, and Boyd et al., McGibbeny et al., and Balkani all transmit the communication signal over all three phases of the 3 φ power supply by means of neutral points at the remote and local sites. 
     In those prior art systems that employ the conductors of the 3 φ power supply line as a conducting path, the signal transmission between the local and remote unit ranges from unidirectional and analog in the case of Boyd, Boyd et al., Farque, and Vandervier et al., to bidirectional and analog in the case of McGibbeny et al. and Balkanli. 
     Other prior art solutions to the problem of providing a communication link between a locally situated control and monitoring unit and a remotely situated control and instrumentation unit have simply included the use of a dedicated conductor (or conductors) for the transmission of dam. Examples of such prior art systems are disclosed in U.S. Pat. Nos. 3,406,359 and 3,991,611 issued to Welz et al. and Marshall, III et al. respectively. Of these prior art systems, Marshall, III et al. utilizes a single conductor for all communication while Welz et al. utilizes a different dedicated conductor for each piece of dam. 
     In those prior art systems utilizing a separate dedicated conducting path for communications, the signal transmission between the local and remote unit varies from the bidirectional serial transmission of digital information in the case of Marshall, III et al. to the unidirectional parallel transmission of analog data in the case of Welz et at. 
     Thus, the prior art solutions to the problem of communication between a remotely located down-hole unit and a locally located surface unit have not included: (1) the transmission of digital data by means of the conductors of the 3 φ power supply line; (2) the simultaneous bidirectional transmission of data (whether digital or otherwise); and/or (3) the generation and transmission of digital data by means of a modulated analog loop current. 
     The present invention overcomes these limitations of the prior art by permitting the simultaneous bidirectional transmission of digital dam, in the form of a modulated D.C. loop current, between a local surface unit and a remote down-hole unit by utilizing the conductors of the 3 φ power supply line as a signal path thereby precluding the need for a separate conducting path and at the same time permitting the rapid and reliable transmission of data between a local and a remote site. 
     SUMMARY OF THE INVENTION 
     The present invention finds utility in industrial or other installations wherein (i) an A.C. powered device is remotely located; (ii) it is desired to monitor certain parameters of interest, such as temperature or pressure, at the remote site; and/or (iii) it is desired to remotely control certain operational functions there. This invention enables the accurate sensing of such parameters of interest and the control of functions at the remote site by means of the bidirectional transmission of digital data between a locally controlled surface unit and a remotely located down-hole unit. Digital data is transmitted between the control and monitoring equipment at the local site on the surface and the instrumentation and control equipment remotely located in the down-hole location by means of the power cable which carries the A.C. power to the remotely located A.C. device; thus, there is no requirement for any additional electrically conducting instrumentation and/or control lines to the remote location. Further, the use of a modulated analog loop current for the transmission of the digital data provides a relatively simple (i.e. inexpensive), rapid, and reliable means of data transmission. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic diagram of a three phase A.C. powered system in which an apparatus in accordance with the present invention is installed. 
     FIG. 2 is a schematic diagram illustrating the operation of the embodiment of the apparatus depicted in FIG. 1. 
     FIG. 3 is a schematic diagram of the surface unit of the apparatus of FIG. 1. 
     FIG. 4 is a schematic diagram of the down-hole unit of the apparatus of FIG. 1. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A data transmission and instrumentation system and apparatus is described which is particularly useful for (i) remotely sensing physical characteristics of interest such as, for example, the pressure and temperature in a down-hole or submersible well pumping system, (ii) remotely controlling the state of switching, or other control devices, such as, for example, solenoid actuated valves or solenoid latches, and/or (iii) providing a reliable means of bidirectional communication between a locally positioned control and monitoring unit and a remotely positioned control and instrumentation unit. As will be apparent from the following detailed description, the inventive concepts disclosed herein are applicable to numerous other instrumentation applications. In the description, like elements in the various FIGURES will be designated by the same numerical designations. 
     A presently preferred embodiment of the invented apparatus is used advantageously in an electric motor powered submersible pumping system to: (i) monitor certain down-hole parameters, such as pressure and temperature, (iii) control certain down-hole equipment, and (iii) to provide bidirectional communication between the down-hole location and surface location to enable the required monitoring and control functions. 
     The presently preferred embodiment of the subject invention is now described with reference to FIG. 1. The submersible pumping system includes a submersible motor and pump assembly 10. The motor is shown symbolically by three-phase A.C. windings 20, Y-connected (a balanced inductor network) and having a neutral, ungrounded node 30; the pump, operatively coupled to the motor, is not individually shown. Although many types of motors and pumps may be operated through use of the present invention, one exemplary combination would be a model DN 280 pump, manufactured and sold by Reda, of Bartlesville, Okla., operated by a 540 series motor, manufactured and sold by Reda. The motor operates on 2350 Volts, drawing 26 Amps, and provides 100 Hp. 
     A down-hole unit 40, described more fully below, is electrically coupled to (i) the neutral node 30 of motor windings 20 by a large inductor 35, and (ii) to earth ground 50. The large inductor 35 filters out the motor A.C. from interfering with communications signals transmitted between the down-hole unit 40 and a surface unit 100. Inductor 35 may, in an embodiment depicted herein, be a 140 Henry inductor. 
     On the surface 120, a conventional A.C. power source 55 supplies power via conductors 75 to the motor windings 20 in the motor and pump assembly 10 and also to an auxiliary three-phase, Y-connected (a balanced inductor network) surface set of windings 90 having a neutral, ungrounded node 70. The surface windings 90 are connected in a configuration identical to that of the motor windings 20; this ensures that the neutral nodes 30 and 70 are held at the same relative potential. Also shown on the surface 120 is the surface unit 100, described more fully below. The surface unit 100 is electrically coupled to the neutral node 70 by a large inductor 110. The large inductor 110 serves to filter out the motor A.C. from interfering with communications signals transmitted between the surface unit 100 and the down-hole unit 40. Once again, inductor 110, in an exemplary embodiment as depicted herein, may be a 150 Henry inductor. 
     Power from the power source 55 is carried to the down-hole motor windings 20 by a power cable 115 which extends into the bore-hole 80. Thus, the down-hole unit 40 is electrically coupled to the surface unit 10 through a circuit comprised of large inductor 35, motor windings 20, power cable 115 with conductors 75, auxiliary windings 90, large inductor 110, and earth ground 50. 
     With reference to FIG. 2, the operation of the depicted embodiment is now described, in particular the means by which the surface unit 100 and the down-hole unit 40 communicate information with one another simultaneously in a bidirectional fashion. 
     The down-hole unit 40 includes a first current measurement circuit 200, a reference resistor 250, and a first serial output circuit 210. The first current measurement circuit 200 includes a first current sensing resistor 202 and a first current measurement signal generator 204. The first serial output circuit 210 includes a first switch assembly 212 and a first preset resistor 214. 
     The surface unit 100 includes a D.C. power supply 220, a second current measurement circuit 230, and a second serial output circuit 240. The second current measurement circuit 230 consists of a second current sensing resistor 232 and a second current measurement signal generator 234. The second serial output circuit 240 includes a second switch assembly 242 and a second preset resistor 244. D.C. power supply 220 provides power for the downhole electronic components. D.C. power supply 220 has a small constant current draw such as on the order of 5 mA. This current draw is largely insignificant relative to the current consumed by the preset resistors. 
     In operation, the current measurement circuits 200 and 230 provide a measurement of the analog loop current 260 which will vary as a function of the position of the switches 242 and 212. This permits each unit (surface unit 100 and down-hole unit 40) to simultaneously transmit and receive digital information. This is accomplished by measuring the analog loop current 260 and transmitting serial data by means of the switches 212 and 242. For example if we assign the following values: 
     First preset resistor 214=75 Ω; 
     Second preset resistor 244=150 Ω; 
     Reference resistor 250=250 Ω; and 
     D.C. power means 220=10 V 
     The following analog loop current measurements (including the above-referenced constant D.C. power supply current of approximately 5 mA) will be determined as a function of the position of the switches 212 and 242: 
     
         ______________________________________                       Analog LoopFirst Switch 212         Second Switch 242                       Current 260______________________________________OPEN          OPEN          26 mACLOSED        OPEN          36 mAOPEN          CLOSE         31 mACLOSED        CLOSE         45 mA______________________________________ 
    
     Since each unit 40 and 100 measures the analog loop current 260, each may determine whether a digital &#34;0&#34; or &#34;1&#34; is being transmitted by the other unit even if the respective unit is itself simultaneously transmitting data via the power cable 115 to the other unit. 
     With reference to FIG. 3, the operation and specific elements of down-hole unit 40 is now described. The down-hole unit 40 includes a first current measurement circuit 200, a reference resistor 250, a first serial output circuit 210, and a first microprocessor controller 300. The first microprocessor controller 300 may be a CDP 1805 microprocessor manufactured by Harris. 
     The first current measurement circuit 200 consists of a first current sensing resistor 202 and a first current measurement signal generator 204 in the form of a first differential amplifier. The first serial output circuit 210 consists of a first switch assembly 212 in the form of a first FET switch and a first preset resistor 214. 
     In operation the first microprocessor controller 300 receives analog inputs 310 and digital inputs 320 and transmits analog outputs 330 and digital outputs 340 locally in the bore-hole location. The first microprocessor controller 300 further communicates with the surface unit 100 by means of the first current measurement circuit 200 and the first serial output circuit 210. 
     The first current measurement circuit 200 permits the first microprocessor controller 300 to measure the analog loop current 260 by means of the first current sense resistor 202 and the first differential amplifier 204. In a manner commonly known in the art, the first differential amplifier 204 produces a first analog loop current measurement signal 370 at its output as a function of the analog loop current 260. The first analog current measurement signal 370 is then received by the first microprocessor controller 300 and converted via software in a conventional manner to digital dam. The conversion of the first analog current measurement signal 370 to digital data could also, of course, be accomplished through conventional hardware. 
     The first serial output circuit 210 permits the first microprocessor controller 300 to transmit digital data by means of the first FET switch 212 and the first preset resistor 214. The operation of the first FET switch 212 is controlled in a manner commonly known in the art by means of a first serial data output signal 360 to open or close the current path through the first FET switch 212 to thereby permit the transmittal of digital data by varying the resistance of the first serial output circuit 210 between two discrete values. As already discussed above, by varying the resistance of the first serial output circuit 210 the analog loop current 260 is also varied, thereby permitting the bidirectional transmission of digital data between the down-hole unit 40 and the surface unit 100. 
     With reference to FIG. 4, the operation and specific elements of surface unit 100 are now described. The surface unit 100 includes a D.C. power supply 220, a second current measurement circuit 230, a second serial output circuit 240, and a second microprocessor controller 400. Once again, the second microprocessor controller 400 may be a 80C196 microprocessor manufactured by Intel Corporation of San Jose, Calif. 
     The second current measurement circuit 230 includes a second current sensing resistor 232 and a second current measurement signal generator 234 in the form of a second differential amplifier. The second serial output circuit 240 includes a second switch assembly 242 in the form of a second FET switch and a second preset resistor 244. 
     In operation the second microprocessor controller 400 receives digital inputs 430 and transmits analog outputs 410 and digital outputs 420 locally at the surface location. The second microprocessor controller 400 further communicates with the down-hole unit 40 by means of the second current measurement circuit 230 and the second serial output circuit 240. 
     The second current measurement circuit 230 permits the second microprocessor controller 400 to measure the analog loop current 260 by means of the second current sense resistor 232 and the second differential amplifier 234. In a manner commonly known in the art, the second differential amplifier 234 produces a second analog loop current measurement signal 440 at its output as a function of the analog loop current 260. The second analog current measurement signal 440 is then received by the second microprocessor controller 400 and converted via software in a conventional manner to digital dam. The conversion of the second analog current measurement signal 440 to digital data could also, of course, be accomplished through conventional hardware. 
     The second serial output circuit 240 permits the second microprocessor controller 400 to transmit digital data by means of the second FET switch 242 and the second preset resistor 244. The operation of the second FET switch 242 is controlled in a manner commonly known in the art by means of a second serial data output signal 450 to open or close the current path through the second FET switch 242 to thereby permit the transmittal of digital data by varying the resistance of the second serial output circuit 240. As already discussed above, by varying the resistance of the second serial output circuit 240 the analog loop current 260 is also varied, thereby permitting the bidirectional transmission of digital data between the down-hole unit 40 and the surface unit 100. 
     A data transmission and instrumentation apparatus has been described for remote use with alternating current devices, such as, for example, a down-hole submersible motor and pump assembly. All communication between the local and remote site is accomplished through the power cable, which carries power to the A.C. device, without the use of additional communication lines. 
     While the invention has been particularly shown and described with reference to preferred embodiments for use in a submersible pumping application, it should be understood that persons skilled in the art may make various changes in form and detail of the present invention without departing from the spirit and scope of the invention; and further, that the principles disclosed are susceptible of other applications which will be apparent to those skilled in the art. This invention, therefore, is not intended to be limited to the particular embodiments herein disclosed.