Variable throat venturi flow meter having a plurality of section-varying elements

An acoustic transceiver assembly including a housing, an oscillator, and a blocking element. The housing has at least one inner wall defining a cavity. The cavity has a first end and a second end defining an axis of said acoustic transceiver assembly. The oscillator is provided in said cavity. The oscillator is provided with a transducer element, and a backing mass positioned adjacent to the transducer element. A blocking element is positioned inside the cavity and adjacent to the oscillator. The blocking element is adapted to restrain a portion of said backing mass at a first pressure to thereby restrain the backing mass from lateral movement relative to the axis of the acoustic transceiver assembly. The blocking element is also adapted to release the backing mass at a second pressure.

Not Applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND AN INCORPORATION-BY-REFERENCE OF THE MATERIAL ON THE COMPACT DISC (SEE §1.52(E)(5))

Not Applicable.

TECHNICAL FIELD

This invention relates generally to telemetry systems and acoustic sensors for use with installations in oil and gas wells or the like. More particularly, but not by way of limitation, the present invention relates to an acoustic transceiver assembly for transmitting and receiving data and control signals between a location down a borehole and the surface, or between downhole locations themselves.

BACKGROUND

One of the more difficult problems associated with any borehole is to communicate measured data between one or more locations down a borehole and the surface, or between downhole locations themselves. For example, in the oil and gas industry it is desirable to communicate data generated downhole to the surface during operations such as drilling, perforating, fracturing, and drill stem or well testing; and during production operations such as reservoir evaluation testing, pressure and temperature monitoring. Communication is also desired to transmit intelligence from the surface to downhole tools or instruments to effect, control or modify operations or parameters.

Accurate and reliable downhole communication is particularly important when complex data comprising a set of measurements or instructions is to be communicated, i.e., when more than a single measurement or a simple trigger signal has to be communicated. For the transmission of complex data it is often desirable to communicate encoded analog or digital signals.

One approach which has been widely considered for borehole communication is to use a direct wire connection between the surface and the downhole location(s). Communication then can be made via electrical signal through the wire. While much effort has been spent on “wireline” communication, its inherent high telemetry rate is not always needed and its deployment can pose problems for some downhole operations.

Wireless communication systems have also been developed for purposes of communicating data between a downhole tool and the surface of the well. These techniques include, for example, communicating commands downhole via (1) electromagnetic waves; (2) pressure or fluid pulses; and (3) acoustic communication. Each of these arrangements are highly susceptible to damage due to the harsh environment of oilfield technology in terms of shocks, loads, temperature, pressures, environmental noise and chemical exposure. As such, there is a need in the oil and gas industry to provide protected and reliable wireless communication systems for transmitting data and control signals between a location down a borehole and the surface, or between downhole locations themselves.

In general, a basic element of the conventional acoustic telemetry system includes one or more acoustic transceiver element, such as piezoelectric element(s), magnetostrictive element(s) or combinations thereof which convert energy between electric and acoustic forms, and can be adapted to act as a source or a sensor. In general, one acoustic transceiver element can be made of one or more piezoelectric elements or magnetostrictive element. With respect to the acoustic transceiver element being made from a stack of piezoelectric elements, such elements are made of brittle, ceramic material, thereby requiring protection from transport and operational shocks. Conventional sonic sources and sensors used in downhole tools are described in U.S. Pat. Nos. 6,466,513, 5,852,587, 5,886,303, 5,796,677, 5,469,736 and 6,084,826, 6,137,747, 6,466,513, 7,339,494, and 7,460,435.

In particular, U.S. Pat. No. 7,339,494 teaches an acoustic telemetry transceiver having a piezoelectric transducer for generating an acoustic signal that is to modulate along a mandrel. The prior art is described as providing an acoustic telemetry transceiver that approximately removes lateral movement (relative to the axis of the drill string), and as being configured to be stable over a wide range of operating temperatures and to withstand large shock and vibrations. Embodiments for achieving such objectives teach an acoustic telemetry transceiver having a backing mass that is housed in a linear/journal bearing, and/or a piezoelectric stack coupled to a tapered conical section of the mandrel of the drill string wherein contact is increased therebetween based on a pressure of a flow of a fluid between the piezoelectric stack and the mandrel.

While the present invention and the prior art taught by U.S. Pat. No. 7,339,494 may be considered to share common objectives of protecting the piezoelectric elements of an acoustic transceiver, the exemplary implementations of the present invention, which will be subsequently described in greater detail, for carrying out such objectives include many novel features that result in a new acoustic transceiver assembly and method which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art devices or methods, either alone or in any combination thereof.

Despite the efforts of the prior art, there exists a need for an acoustic transceiver assembly adapted to withstand the heavy shocks and vibrations often associated with the transportation and operation of a downhole tubing string. It is therefore desirable to provide an improved acoustic transceiver assembly with integrated protective features without sacrificing performance and sensitivity.

SUMMARY OF THE DISCLOSURE

In one aspect, the present invention is directed to an acoustic transceiver assembly including a housing, an oscillator, and a blocking element. The housing has at least one inner wall defining a cavity. The cavity has a first end and a second end defining an axis of the acoustic transceiver assembly.

The oscillator is provided in the cavity. The oscillator preferably includes a transducer element, and a backing mass. The transducer element is positioned at the first end of the cavity, and the backing mass is positioned adjacent the transducer element. The transducer element is preferably disposed between the backing mass and the first end of the cavity.

The blocking element is positioned adjacent the oscillator in the cavity. The blocking element is adapted to restrain a portion of the backing mass from lateral movement relative to the axis of the acoustic transceiver assembly, and to permit oscillations of the backing mass.

In one aspect, the blocking element restrains the backing mass at a first pressure and releases the backing mass at a second pressure to permit oscillations of the backing mass. The second pressure may be higher than the first pressure. Moreover, the first pressure may be atmospheric pressure, and the second pressure may be hydrostatic pressure.

In a further aspect, the acoustic transceiver assembly further includes at least one blocking spring biased against the blocking element, and an equalizing chamber having a port hole open to receiving the first pressure and/or the second pressure.

In an even further aspect, the acoustic transceiver assembly may include at least one seal for sealing off the equalizing chamber.

In another aspect, the oscillator of the acoustic transceiver assembly may further include at least one preloading spring having a first end coupled to the backing mass and a second end coupled to the first end of the cavity.

In yet another aspect, the present invention is directed to a downhole tool including a sensor for monitoring a downhole parameter, an acoustic transceiver assembly as described hereinbefore in communication with the sensor, and a blocking element.

In one aspect, the blocking element is positioned adjacent the oscillator in the cavity. The blocking element is therefore adapted to restrain a portion of the backing mass from lateral movement relative to the axis of the acoustic transceiver assembly, and to permit oscillations of the backing mass.

In another aspect, the blocking element restrains the backing mass at a first pressure and releases the backing mass at a second pressure to permit oscillations of the backing mass. The second pressure may be higher than the first pressure. Moreover, the first pressure may be atmospheric pressure, and the second pressure may be hydrostatic pressure.

In a further aspect, the present invention is directed to an acoustic transceiver assembly including a housing, an oscillator, and a blocking element. The housing has at least one inner wall defining a cavity. The cavity has a first end and a second end defining an axis of the acoustic transceiver assembly.

The oscillator is provided in the cavity. The oscillator preferably includes a piezoelectric element, and a backing mass. The piezoelectric element is positioned at the first end of the cavity, and the backing mass is positioned adjacent the piezoelectric element. The piezoelectric element is preferably disposed between the backing mass and the first end of the cavity.

The blocking element is positioned adjacent the oscillator in the cavity. The blocking element is adapted to restrain a portion of the backing mass from lateral movement relative to the axis of the acoustic transceiver assembly, and to permit oscillations of the backing mass.

In one aspect, the blocking element restrains the backing mass at a first pressure and releases the backing mass at a second pressure to permit oscillations of the backing mass. The second pressure may be higher than the first pressure. Moreover, the first pressure may be atmospheric pressure, and the second pressure may be hydrostatic pressure.

In another aspect, the acoustic transceiver assembly further includes at least one blocking spring biased against the blocking element, and an equalizing chamber having a port hole open to receiving the first pressure and/or the second pressure.

In yet another aspect, the acoustic transceiver assembly may include at least one seal for sealing off the equalizing chamber.

In another aspect, the oscillator of the acoustic transceiver assembly may further include at least one preloading spring having a first end coupled to the backing mass and a second end coupled to the first end of the cavity.

In a further aspect, the present invention is directed to a method for making an acoustic transceiver assembly for introducing acoustic signals into an elastic media positioned in a well bore. The method includes the steps of: forming an oscillator, and suspending the oscillator in a housing.

The step of forming the oscillator may be performed by acoustically coupling a backing mass to a transducer element. And the step of suspending the oscillator in a housing may be performed by positioning a blocking element adjacent to the backing mass, wherein the blocking element restrains the backing mass at a first pressure and releases the backing mass at a second pressure.

In an even further aspect, the method may include the steps of: forming an equalizing chamber between the blocking element and the housing; and forming at least one port hole in the equalizing chamber and through the housing. Moreover, the at least one port hole can be adapted to receive the first and/or second pressures.

In another aspect, the method may further include the step of forming at least one seal for sealing off the equalizing chamber.

In one aspect, the blocking element may be conical.

In another aspect, the present invention is directed to a method for making a downhole modem. The method preferably includes the steps of: forming an oscillator by acoustically coupling a backing mass to a transducer element, and suspending the oscillator in a housing with a blocking element. The blocking element is preferably positioned adjacent to the backing mass, wherein the blocking element restrains the backing mass at a first pressure and releases the backing mass at a second pressure.

The method may further include the step of connecting the transducer element to control electronics suitable for causing the oscillator to transmit acoustic signals into an elastic media and receive acoustic signals from the elastic media to form the downhole modem.

These, together with other aspects, features, and advantages of the present invention, along with the various features of novelty, which characterize the present invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. The above aspects and advantages are neither exhaustive nor individually or jointly critical to the spirit or practice of the present invention. Other aspects, features, and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description in combination with the accompanying drawings, illustrating, by way of example, the principles of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not restrictive.

DETAILED DESCRIPTION

Numerous applications of the present invention are described, and in the following description, numerous specific details are set forth. However, it is understood that implementations of the present invention may be practiced without these specific details. Furthermore, while particularly described with reference to transmitting data between a location downhole and the surface during testing installations, aspects of the present invention are not so limited. For example, some implementations of the present invention are applicable to transmission of data from the surface during drilling, in particular measurement-while-drilling (MWD) and logging-while-drilling (LWD). Additionally, some aspects of the present invention are applicable throughout the life of a wellbore including, but not limited to, during drilling, logging, drill stem testing, fracturing, stimulation, completion, cementing, and production.

In particular, however, the present invention is applicable to testing installations such as are used in oil and gas wells or the like.FIG. 1shows a schematic view of such an installation. Once the well has been drilled, the drilling apparatus is removed from the well and tests can be performed to determine the properties of the formation though which the well has been drilled. In the example ofFIG. 1, the well10has been drilled, and lined with a steel casing 12 (cased hole) in the conventional manner, although similar systems can be used in uncased (open hole) environments. In order to test the formations, it is necessary to place testing apparatus in the well close to the regions to be tested, to be able to isolate sections or intervals of the well, and to convey fluids from the regions of interest to the surface. This is commonly done using an elastic media13, such as a jointed tubular drill pipe14which extends from the well-head equipment16at the surface (or sea bed in subsea environments) down inside the well10to a zone of interest. Although the elastic media13will be described herein with respect to the drill pipe14, it should be understood that the elastic media13can take other forms in accordance with the present invention, such as production tubing, a drill string, a tubular casing, or the like. The well-head equipment16can include blow-out preventers and connections for fluid, power and data communication.

A packer18is positioned on the drill pipe14and can be actuated to seal the borehole around the drill pipe14at the region of interest. Various pieces of downhole equipment20for testing and the like are connected to the drill pipe14, either above or below the packer18, such as a sampler22, or a tester valve24. The downhole equipment20may also be referred to herein as a “downhole tool.” Other Examples of downhole equipment20can include:Further packersCirculation valvesDownhole chokesFiring headsTCP (tubing conveyed perforator) gun drop subsPressure gaugesDownhole flow metersDownhole fluid analyzersEtc.

As shown inFIG. 1, the packer18can be located below the sampler22and the tester valve24. The downhole equipment20is shown to be connected to a downhole modem25including an acoustic transceiver assembly26(shown inFIG. 3), which can be mounted in a gauge carrier28positioned between the sampler22and tester valve24. The acoustic transceiver assembly26, also known as an acoustic transducer, is an electro-mechanical device adapted to convert one type of energy or physical attribute to another, and may also transmit and receive, thereby allowing electrical signals received from downhole equipment20to be converted into acoustic signals for transmission to the surface, or for transmission to other locations of the drill pipe. In addition, the acoustic transceiver assembly26may operate to convert acoustic tool control signals from the surface into electrical signals for operating the downhole equipment20. The term “data,” as used herein, is meant to encompass control signals, tool status, sensed information and any variation thereof whether transmitted via digital or analog signals.

FIG. 2illustrates a schematic diagram of an oscillator36, implementations of which are adapted for placement in or on downhole tools20, generally, and as part of the acoustic transceiver assembly26, in particular. The oscillator36is shown to include a transducer element38, and a backing mass40calibrated to operate at a particular resonant frequency. As will be discussed in more detail below, the acoustic transceiver assembly26may also include at least one preloading spring42, a housing44(seeFIG. 3) and a blocking element46.

The transducer element38can be constructed in a variety of manners suitable for converting electrical signals to acoustic signals and also for converting acoustic signals to electrical signals. Examples of suitable transducer elements include a piezoelectric element, a magnetostrictive element or the like. When the transducer element38is a piezoelectric element, such element is typically constructed of multiple layers of ceramic material which can be glued together, or held in compression, to thereby create a stack (not shown). The glue can be adapted to prevent the layers of the stack from moving side to side relative to each other as in one embodiment the layers must remain in proper alignment for satisfactory performance. However, due to the brittle nature of the typically ceramic, piezoelectric transducer element, and the harsh environment of oilfield technology, prior art methods of protecting the oscillator36may be unsatisfactory during transportation and installation of the downhole tools containing the oscillator36. For example, during lateral movement or shock along an axis56, the backing mass40appears to be mounted as a cantilever, and can generate important constraints on the transducer element38. In one embodiment, the present invention will solve such problems by restraining the backing mass40in the event of lateral shocks at the surface, and freeing the backing mass40once the acoustic transceiver assembly26is at a certain depth downhole.

FIG. 3shows a schematic diagram of the acoustic transceiver assembly26in more detail. Although not shown in specific detail, the acoustic transceiver assembly26typically functions as both a transmitter and a receiver that share common or discrete circuitry or a single housing; although, in particular instances the acoustic transceiver assembly26may be adapted or used only as a transmitter or a receiver. The housing44of the acoustic transceiver assembly26may be adapted for placement in a wall, adjacent to a wall, or inside the tubing of downhole equipment20. The backing mass40may be constructed of one or more of a number of different materials, including tungsten, steel, aluminum, stainless steel, depleted uranium, lead, or the like. The backing mass40is preferably made from high density material, such as tungsten alloys, steel, and the like and may be of any shape, such as, but not limited to, cylindrical, arcuate, rectangular, frusto-conical (as shown inFIG. 3) or square.

The housing44has a least one inner wall80to define a cavity82. The housing44and cavity82have a first end84and a second end86defining the axis52of the acoustic transceiver assembly26.

The oscillator36is provided in the cavity82defined by the inner wall80of the housing44. As discussed above, generally, the oscillator36is provided with the transducer element38, and the backing mass40. In an alternative embodiment, however, the oscillator36may include at least one preloading spring42(two being shown inFIG. 3and identified by reference numerals42aand42b). A first end of the preloading spring42is shown as being coupled to the backing mass40, and a second end of the preloading spring42is shown as being coupled near the first end84of the cavity82. It should be understood, however, that the preloading spring42may be provided in the interior of the transducer element38. The backing mass40is preferably acoustically coupled to the transducer element38(i.e., rigidly connected such that the frequency of the backing mass40has an impact on the frequency of the transducer element38), and the preloading spring(s)42may be adapted to provide a bias to the transducer element38so that the transducer element38can be maintained under compression.

The acoustic transceiver assembly26can further include a blocking element46positioned at one end of the oscillator36and adapted to restrain the backing mass40by, for example, engaging a portion of the backing mass40at a first pressure, e.g., atmospheric pressure, e.g., at the surface, and releasing the backing mass40at a second pressure, e.g., hydrostatic pressure, e.g., at a certain location down hole. In one version, the second pressure can be greater than the first pressure. As stated above, blocking element46is adapted to restrain the backing mass40, which would be understood to mean that the blocking element46can be configured to, for example, either acting independently or in cooperation with additional features and/or elements described herein, be movable within housing44along axis52in response to changes in ambient pressure outside of the acoustic transceiver assembly26. For example, in a preferred embodiment, the acoustic transceiver assembly26further includes an equalizing chamber62which is connected to the ambient pressure (e.g., outside of the housing44) via at least one port hole60, wherein the port hole60is positioned in, i.e., through, the housing44. The at least one port hole60would be understood to be sized and/or shaped such that the ambient pressure surrounding the acoustic transceiver assembly26would pass through the at least one port hole60into the equalizing chamber62. Further modifications to the at least one port hole60can, for example, include such features (not shown) as screens, filters, valves, extension tubing and the like.

The ambient pressure, which may range from below atmospheric to above hydrostatic pressure, enters the equalizing chamber62through the port hole60in the housing44. The equalizing chamber62can be preferably sealed via a plurality of seals70(two being shown inFIG. 3and identified by reference numeral70aand70b) so as to allow the remainder of the cavity82of the acoustic transceiver assembly26to be maintained at a separate pressure, such as atmospheric or vacuumed. If included, the plurality of seals70would be adapted to permit longitudinal movement of the blocking element46along axis52while maintaining separate pressures in cavity82, blocking cavity82a(discussed below) and equalizing chamber62.

As would be understood, when the equalizing chamber62includes the plurality of seals70, the cavity82of the acoustic transceiver assembly26would then be further subdivided to include the blocking cavity82a. Thus, as shown in the example ofFIG. 3, the cavity82can be defined as extending from near the first end84to the seal70b. The blocking cavity82acan be defined as extending from near the second end86to the seal70a. The equalizing chamber62can be defined as extending between the seals70aand70b. The cavity82and the blocking cavity82acan be at a predetermined, fixed pressure, e.g., atmospheric pressure or a vacuum, whereas the equalizing chamber62can be exposed to the ambient pressure via port hole60. However, as would be understood in the art, other configurations of the cavity82, blocking cavity80a, equalizing chamber62and/or a plurality of seals70can be used to achieve the described functions without departing from the scope and intent of the present invention.

As stated above, the blocking element46is positioned inside the cavity82defined by the inner wall80of the housing44and adjacent to the oscillator36. In one embodiment, which is shown inFIG. 3, the blocking element46can further be defined as including a first outside cross-sectional distance90and a second outside cross-sectional distance92wherein the first outside cross-sectional distance90is smaller than the second outside cross-sectional distance92. As shown inFIG. 3, the first and second outside cross-sectional distances90and92cooperate to form a shoulder94which can be perpendicular to axis52. As would be understood, the inner wall80can be configured to also include a shoulder95which can be adapted to receive the shoulder94of the blocking element46. In one embodiment, the shoulder94can be configured such that the blocking element46is prevented from extending away from the second end86and towards the backing mass40so far as to impact and/or damage the oscillator36. In another embodiment, the port hole60can be positioned such that it would not be blocked or otherwise obstructed by blocking element46when moved toward the oscillator36. The shoulder94of the blocking element46, and the corresponding shoulder95of the inner wall80, when separated, can thereby form the equalizing chamber62. However, as would be readily understood in the art, other configurations and/or shapes of the blocking element46and the corresponding inner wall80can be used, e.g., such as sloped, stepped and the like.

In another preferred embodiment, the port hole60is positioned such that when a second pressure higher than the pressure in the cavity82and blocking cavity82aenters the equalizing chamber62via the at least one port hole60, the resultant increase in pressure inside the equalizing chamber62operates to expand said chamber62and thereby force the blocking element46longitudinally along axis52toward the second end86, thereby releasing the oscillator36and allowing it to move freely.

In this version, when the second pressure, preferably hydrostatic, which is higher than the pressure in the cavity82and blocking cavity82a, enters the equalizing chamber62via the port hole60, the resultant pressure within the equalizing chamber62increases and thereby exerts a force acting against the blocking element46. In particular, the force acts to expand the equalizing chamber62to thereby push the blocking element46towards the second end86along the axis52, i.e., the force acts to separate the backing mass40and the blocking element46to thereby release the backing mass40and allow it to move freely at the second pressure. Similarly, when a first pressure which is lower than or equal to the pressure in the cavity82and blocking cavity82aenters the equalizing chamber62, the blocking element46is allowed to move back towards the first end84along the axis52to thereby restrain a portion of the backing mass40to prevent movement at the first pressure.

As is described above, the equalizing chamber62is preferably sealed by a plurality of seal(s)70. However, it should be understood that the equalizing chamber62can also be sealed via other means known in the art. Similarly, other methods can be used to permit the blocking element46to restrain the backing mass40at a first pressure and release the backing mass40at a second pressure, as are discussed below.

As shown inFIG. 3and described above, the blocking element46can optionally be biased using a plurality of blocking springs72(two being shown inFIG. 3and identified by reference numerals72aand72b) calibrated to push the blocking element46against the backing mass40at the first pressure, preferably atmospheric, thereby restraining the backing mass40from lateral movement at such first pressure. As the ambient pressure surrounding the acoustic transceiver assembly26increases, e.g., the acoustic transceiver assembly26is lowered downhole, the ambient pressure entering the equalizing chamber62likewise increases. The increased pressure allows the blocking element46to apply a greater force to the blocking springs72, thereby releasing the backing mass40and allowing the backing mass40and oscillator36to freely vibrate.

While the blocking element46is shown to be of a shape to mate with the backing mass40, it is to be understood that the blocking element46may be of any shape so as to prevent the oscillator36from lateral movement at a first pressure, and release the oscillator36at a second pressure. In particular, any of the aforementioned corresponding shapes can be used without departing from the scope and intent of the present invention.

In a preferred embodiment of the present invention, to make the acoustic transceiver assembly26compact, the backing mass40is advantageously made of a high-density alloy, such as tungsten carbide.

In order to increase the reliability of the transducer element38, the radial motion of the various parts of the acoustic transceiver assembly26should remain as small as possible. Therefore, close tolerances are preferably used during the manufacturing of the components described therein.

Referring now toFIG. 4, shown therein is an alternate embodiment of an acoustic transceiver assembly designated by reference numeral26a. As shown therein, the acoustic transceiver assembly26ais constructed without the blocking spring(s)72, the blocking cavity82a, the at least one port hole60and equalizing chamber62, as well as the associated seal(s)70, shown inFIG. 3. In this alternate embodiment, the acoustic transceiver assembly26aincludes the oscillator36aand the adjacent blocking element46a. As would be understood, this embodiment does not operate via the first and second pressures, and features associated therewith. Instead, this alternate embodiment achieves the above stated goals and/or functions by the use of closely machined tolerances between the blocking element46aand backing mass40a. That is, the blocking element46aand backing mass40acan be sized and shaped such that the blocking element46arestricts or limits movement of the oscillator along axis56but allows movement, e.g., oscillation along axis52. For example, such functionality can be achieved via closely machined tolerances of the relevant components during the manufacturing and/or assembly process. Other possible variations can include a telescoping arrangement, and/or a flexible substance (not shown) inserted between the blocking element46aand the backing mass40a.

Referring now toFIG. 5, shown therein is a section of the drill pipe14having multiple downhole modems25(designated by reference numerals25aand25b) mounted thereto and spatially disposed so as to transmit and/or receive acoustic signals there between via the drill pipe14. It should be noted that the drill pipe14is an example of the elastic media13that transmits acoustic or stress signals. The downhole modems25aand25bare shown as being attached to the outside of the drill pipe14using a pair of clamps162and164(which are designated inFIG. 5as162a,162b,164a, and164b). When actuated by a signal, such as a voltage potential initiated by a sensor, the downhole modem25which is mechanically mounted onto the drill pipe14imparts a stress wave which may also be now known as an acoustic wave into the drill pipe14. Because metal drill pipe propagates stress waves, the downhole modems25aand25bincluding the acoustic transceiver assemblies26can be used to transmit the acoustic signals between each other, or to the surface. Furthermore, the downhole modems25aand25bincluding the acoustic transceiver assembly26can be used during all aspects of well site development and/or testing regardless of whether drilling is currently present. It should be noted that in lieu of the drill pipe14, other appropriate tubular member(s) (elastic media13) may be used, such as production tubing, and/or casing to convey the acoustic signals.

Referring toFIG. 6, the downhole modems25aand25binclude control electronics169including transmitter electronics170and receiver electronics172. The transmitter electronics170and receiver electronics172may also be located in the housing44and power is provided by means of a battery, such as a lithium battery174. Other types of power supply may also be used.

The transmitter electronics170are arranged to initially receive an electrical output signal from a sensor176, for example from the downhole equipment20provided from an electrical or electro/mechanical interface. Such signals are typically digital signals which can be provided to a microcontroller178which modulates the signal in one of a number of known ways such as FM, PSK, QPSK, QAM, and the like. The resulting modulated signal is amplified by either a linear or non-linear amplifier180and transmitted to the transducer element38so as to generate an acoustic signal in the material of the drill pipe14.

The acoustic signal that passes along the drill pipe14as a longitudinal and/or flexural wave comprises a carrier signal with an applied modulation of the data received from the sensors176. The acoustic signal typically has, but is not limited to, a frequency in the range 1-10 kHz, and is configured to pass data at a rate of from about 1 bps to about 200 bps. The data rate is dependent upon conditions such as the noise level, carrier frequency, and the distance between the downhole modems25aand25b. A preferred embodiment of the present invention is directed to a combination of a short hop acoustic telemetry system for transmitting data between a hub located above the main packer18and a plurality of downhole equipment such as valves below and/or above said packer18. Either one or both of the downhole modems25aand25bcan be configured as a repeater. Then the data and/or control signals can be transmitted from the hub to a surface module either via a plurality of repeaters as acoustic signals or by converting into electromagnetic signals and transmitting straight to the top. The combination of a short hop acoustic with a plurality of repeaters and/or the use of the electromagnetic waves allows an improved data rate over existing systems. The system10may be designed to transmit data as high as 200 bps. Other advantages of the present system exist.

The receiver electronics172are arranged to receive the acoustic signal passing along the drill pipe14produced by the transmitter electronics170of another modem. The receiver electronics172are capable of converting the acoustic signal into an electric signal. In a preferred embodiment, the acoustic signal passing along the drill pipe14excites the transducer element38so as to generate an electric output signal (voltage); however, it is contemplated that the acoustic signal may excite an accelerometer184or an additional transducer element38so as to generate an electric output signal (voltage). This signal can be, for example, essentially an analog signal carrying digital information. The analog signal is applied to a signal conditioner 190, which operates to filter/condition the analog signal to be digitalized by an A/D (analog-to-digital) converter192. The A/D converter192provides a digital signal which can be applied to a microcontroller194. The microcontroller194is preferably adapted to demodulate the digital signal in order to recover the data provided by the sensor176connected to another modem, or provided by the surface. Although shown and described as separate microcontrollers178and194, each microcontroller can alternatively be incorporated into a single microcontroller (not shown) performing both functions. The type of signal processing depends on the applied modulation (i.e. FM, PSK, QPSK, QAM, and the like).

The modem25can therefore operate to transmit acoustic data signals from the sensors in the downhole equipment20along the drill pipe14. In this case, the electrical signals from the equipment20are applied to the transmitter electronics170(described above) which operate to generate the acoustic signal. The modem25can also operate to receive acoustic control signals to be applied to the downhole equipment20. In this case, the acoustic signals are demodulated by the receiver electronics172(described above), which operate to generate the electric control signal that can be applied to the equipment20.

In order to support acoustic signal transmission along the drill pipe14between the downhole location and the surface, a series of repeater modems25a,25b, etc. may be positioned along the drill pipe14. These repeater modems25aand25b(seeFIG. 1) can operate to receive an acoustic signal generated in the drill pipe14by a preceding modem25and to amplify and retransmit the signal for further propagation along the drill pipe14. The number and spacing of the repeater modems25aand25bwill depend on the particular installation selected, for example on the distance that the signal must travel. A typical spacing between the modems25aand25bis around 1,000 ft, but may be much more or much less in order to accommodate all possible testing tool configurations. When acting as a repeater, the acoustic signal is received and processed by the receiver electronics172and the output signal is provided to the microcontroller194of the transmitter electronics170and used to drive the transducer element38in the manner described above. Thus an acoustic signal can be passed between the surface and the downhole location in a series of short hops.

The role of a repeater modem, for example,25aand25b, is to detect an incoming signal, to decode it, to interpret it and to subsequently rebroadcast it if required. In some implementations, the repeater modem25aor25bdoes not decode the signal but merely amplifies the signal (and the noise). In this case the repeater modem25aor25bis acting as a simple signal booster.

Repeater modems25aand25bare positioned along the tubing/piping string14. The repeater modem25aor25bwill either listen continuously for any incoming signal or may listen from time to time.

The acoustic wireless signals, conveying commands or messages, propagate in the transmission medium (the drill pipe14) in an omni-directional fashion, that is to say up and down. It is not necessary for the modem25to know whether the acoustic signal is coming from another repeater modem25aor25babove or below. The direction of the message is preferably embedded in the message itself. Each message contains several network addresses: the address of the transmitter electronics170(last and/or first transmitter) and the address of the destination modem25at least. Based on the addresses embedded in the messages, the repeater modems25aor25bwill interpret the message and construct a new message with updated information regarding the transmitter electronics170and destination addresses. Messages will be transmitted from repeater modem to repeater modem and slightly modified to include new network addresses.

Referring again toFIG. 1, a surface modem200is provided at the well head16which provides a connection between the drill pipe14and a data cable or wireless connection202to a control system204that can receive data from the downhole equipment20and provide control signals for its operation.

In the embodiment ofFIG. 1, the acoustic telemetry system10is used to provide communication between the surface and the downhole location. In another embodiment, acoustic telemetry can be used for communication between tools in multi-zone testing. In this case, two or more zones of the well are isolated by means of one or more packers18. Test equipment20is located in each isolated zone and corresponding modems25are provided in each zone case. Operation of the modems25allows the equipment20in each zone to communicate with each other as well as the equipment in other zones as well as allowing communication from the surface with control and data signals in the manner described above.

Embodiments of the present invention with respect to the microcontrollers178and194, and the control system204may be embodied utilizing machine executable instructions provided or stored on one or more machine readable medium. A machine-readable medium includes any mechanism which provides, that is, stores and/or transmits, information accessible by the microcontrollers178and194or another machine, such as the control system204including one or more computer, network device, manufacturing tool, or the like or any device with a set of one or more processors, etc., or multiple devices having one or more processors that work together, etc. In an exemplary embodiment, a machine-readable medium includes volatile and/or non-volatile media for example read-only memory, random access memory, magnetic disk storage media, optical storage media, flash memory devices or the like.

Such machine executable instructions are utilized to cause a general or special purpose processor, multiple processors, or the like to perform methods or processes of the embodiments of the present invention.

It should be understood that the components of the inventions set forth above can be provided as unitary elements, or multiple elements which are connected and/or otherwise adapted to function together, unless specifically limited to a unitary structure in the claims. For example, although the backing mass40is depicted as a unitary element, the backing mass40could be comprised of multiple discrete elements which are connected together using any suitable assembly, such as a system of threads. As another example, although the housing44is depicted as a unitary element, it should be understood that the housing44could be constructed of different pieces and/or sleeves which were connected together utilizing any suitable technology.

From the above description it is clear that the present invention is well adapted to carry out the disclosed aspects, and to attain the advantages mentioned herein as well as those inherent in the present invention. While presently preferred implementations of the present invention have been described for purposes of disclosure, it will be understood that numerous changes may be made which readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the present invention disclosed.