WO2015171528A1

WO2015171528A1 - Mud pulse telemetry device

Info

Publication number: WO2015171528A1
Application number: PCT/US2015/029117
Authority: WO
Inventors: Richard CHEVELDAVE; John J. Cooley; Riccardo Signorelli; Paul Feluch
Original assignee: Fastcap Systems Corporation
Priority date: 2014-05-03
Filing date: 2015-05-04
Publication date: 2015-11-12

Abstract

In one aspect, an apparatus is disclosed including: a power supply and a rotary mud pulse telemetry device. The rotary mud pulse telemetry device includes a drive motor configured to be powered by the power supply and a rotating actuator configured to be driven by the drive motor to modulate the flow of fluid through a borehole to encode information from a down hole location. In some embodiments, the power suppiy and drive motor are configured to cooperate to drive the rotating actuator with a high torque.

Description

MUD PULSE TELEMETRY DEVICE

CROSS REFERENCE TO RELATED APPLICATIONS

[i j The present application claims priority to U.S. Provisional Patent Application No. 61/988,205, filed May 3, 2014 the entire contents of which are incorporated herein by reference. The present application is also related to the applications listed in Table 2 below the entire contents of each of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

[2] This disclosure herein relates to exploration for oil and gas and geothermal and other subterranean resources and, in particular, to downhoSe mud pulse telemetry devices, systems, and methods of their use.

BACKGROUND

[3] In the exploration for oil and gas, it is necessary to drill a wellbore into the Earth. While drilling of the wellbore permits individuals and companies to evaluate sub- surface materials and to extract desired hydrocarbons, many problems are encountered.

[4] For example, it is well known that the "easy oil" is generally gone. Exploration now requires searching to greater depths than ever before. This necessitates drilling deeper and deeper, and thus into harsh environments, such as those having temperatures ranging from 200 degrees Celsius up to or in excess of 300 degrees Celsius. Generally, present day

instrumentation is not built to operate in such an environment, and will fail well before reaching ambient temperatures within this range.

[5] The growing complexity of down hole instrumentation further complicates this problem. That is, as technology continues to improve, exploration is making use of more instrumentation than ever before. With this usage comes an increased demand for power down hole. In addition, down hole instruments becoming available have greater instantaneous (or pulse or peak) power requirements. For example, certain down hole instruments may be able to use an existing down hole power source while operating in a first mode, e.g., a standby mode, but require a high power pulse, which existing power sources cannot readily meet, during a second mode of operation, e.g., a data collection or transmission mode.

[6] Unfortunately, many of the known down hole power sources have substantial drawbacks. For example, various types of batteries suffer catastrophic failure at elevated temperature, and can thus destroy instrumentation. Meeting the high instantaneous (or peak or pulse) power demand of certain down hole instruments requires high rate batteries, which typically have a lower capacity than low or medium rate batteries and are more susceptible to catastrophic failure at elevated temperatures. Additionally, batteries currently used in down hole applications are typically not rechargeable and may be quite expensive. When a battery requires replacement, e.g., due to failure or charge depletion, a drilling operation must be halted while the drillstring, typically thousands of linear feet, is extracted from the well to gain access to the batteries and any instrumentation that may also require replacement. This operation is time consuming and expensive, and potentially hazardous.

[7] Another currently available down hole power source is a down hole generator, e.g., a turbine-based generator. Downhole generators may not suffer from the same temperature limitations as available down hole battery technologies, but down hole electrical generators are highly complex and expensive devices. For example, a typical high temperature, high pressure down hole turbine generator is designed to withstand temperatures up to 200 °C to 300 °C, pressures in the thousands of pounds per square inch (psi), shock and vibrational forces up to several hundred g, and exposure to corrosive chemicals present in the drilling mud. Thus, down hole generators are typically constructed out of expensive, highly engineered materials, similar to those found in expensive jet engines or other gas turbines. In terms of electrical performance, down hole generators also suffer from many of the same limitations as batteries, being unable to provide consistently high power pulses to meet the requirements of many down hole instruments.

[8] Mud Pulse ("MP") telemetry tools are an example of a class of downhole instruments with complex power requirements, particularly pulse power requirements. In MP telemetry information is transmitted by mechanically varying the pressure of the drilling fluid (or mud) in the wellbore. In some applications, it may be desirable to provide high pulsed power to an MP telemetry device, e.g., to power a motor to provide high torque to a rotary actuator for modulating the flow of drilling fluid.

[9] In some drilling applications, lost circulation occurs when drilling fluid flows into one or more geological formations instead of returning up the borehole of the well for

recirculation. Lost circulation can be a serious problem during the drilling of an oil well or gas well. In some cases an additive know as Loss Circulation Material ("LCM") is added to the drilling fluid to reduce or eliminate drilling fluid loss. However, in some embodiments, the LCM material may interfere with or prevent the operation of an MP telemetry device. In some applications, it may be desirable to provide high pulsed power to an MP telemetry device, e.g., to power a motor to provide high torque to a rotary actuator to clear obstructions or otherwise mitigate interference caused by LCM.

[10] Therefore, a high power MP telemetry device is needed that is capable of efficiently and reliably providing MP telemetry signals in a down hole environment, e.g., those using LCM and/or where temperatures range from ambient environmental temperatures up to about 200 °C Celsius or higher, including up to about 300 °C. SUMMARY

[11] In one aspect, a mud pulse telemetry apparatus is provided that may be positioned down hole, e.g., during a drilling operation, and used to encode and transmit information to be detected and decoded to a more up hole (e.g., surface) position.

[12] In some embodiments, the telemetry apparatus includes a power supply and a rotary mud pulser device. The mud pulser device may include a drive motor configured to be powered by the power supply and a rotating actuator configured to be driven by the drive motor to modulate the flow of fluid through a borehole to encode down hole information.

[13] In some embodiments, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a high level of torque. For example, in some embodiments, the use of an ultracapacitor based rechargeable energy storage and a non-compensated rotary pulser of the type described herein (e.g., featuring a robust low friction drive shaft seal), may synergistically allow for the generation of a high level of torque.

114] In some embodiments, the rotating actuator is driven with a torque of at least 100 inch pounds, 200 inch pounds, 300 inch pounds, 400 inch pounds, 500 inch pounds, 750 inch pounds, 1,000 inch pounds, 1,250 inch pounds, 1,500 inch pounds, 1,750 inch pounds, 2,000 inch pounds, or more, e.g., in the range of 100 inch pounds to 2,000 inch pounds or any subrange thereof.

[15] In some embodiments, a method is disclosed for transmitting information from a drill string positioned at a down hole location in a bore hole to a surface location. The drill string having a flow passage through which a drilling fluid flows .The method includes the steps of: providing a telemetry apparatus of the type described herein approximate the down hole location, and modulating a flow of the drilling fluid using the telemetry apparatus to encode the information to be transmitted to the surface location.

[16] In some embodiments, modulating the flow of the drilling fluid includes causing a power supply and a drive motor to cooperate to drive a rotating actuator with a high torque level, as described herein.

[17] In another aspect, a mud pulse telemetry kit is disclosed that includes a power supply module, a rotary mud pulse telemetry device module, and at least one other device such as a linear mud pulse telemetry device module (not shown). The power supply module may be configured to be selectively attachable to each of the rotary mud pulse telemetry device module and the other device.

[18] Various embodiments may include any of the elements, features, components, steps, etc. described herein, either alone, or in any suitable combination.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

119] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing exemplary and other features and advantages are apparent from the following detailed description taken in conjunction with the accompanying drawings.

[20] FIG. 1 A is an illustration of an exemplary mud pulse telemetry apparatus featuring a non-compensated rotary pulser e.g., of the type further illustrated in FIGS. 2A-13.

[21] FIG. IB is a functional diagram of the apparatus of FIG. 1A.

[22] FIG. 2 A is a diagram, partially schematic, showing a drilling operation employing the mud pulse telemetry system in accordance with the present invention.

[23] FIG. 2B is a schematic diagram of the mud pulser telemetry system in accordance with the present invention.

[24] FIG. 3 is a diagram, partially schematic, showing the basic mechanical arrangement of a pulser according to the current invention.

[25] FIGS . 4-9 are consecutive portions of a longitudinal cross-section through the pulser and a portion of the drilling string at the bottom hole location.

[26] FIG. 10 is a diagrammatic, transverse cross-sectional view taken along line 10-10 in FIG. 3 showing the rotor and stator in accordance with the pulser of the present invention;.

[27] FIG. 11 is the diagrammatic transverse cross-sectional view of FIG. 10 showing the rotor in a secondary position with respect to the stator.

[28] FIG. 12 is an enlarged, detailed cross-section view of a seal in accordance with the present invention.

[29] FIG. 13 is a perspective exploded view of a partial section of the seal.

[30] FIGS . 14A-14C show an alternate embodiment of the seal 80 featuring a cartridge configuration. FIG. 14 A is a perspective view. FIG. 14B is a side cross sectional view. FIG. 14C is an exploded perspective view.

[31] FIG. 15 is a perspective view of an angular position detector.

[32] FIG. 16 is an exploded view of a stinger and mules shoe connection

[33] FIG. 17 is a perspective view of a fin cutter element.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[34] Referring to FIGS. 1A and IB, in some embodiments, a mud pulse ("MP") telemetry apparatus 1 is provided that may be positioned down hole, e.g., during a drilling operation, and used to encode and transmit information to be detected and decoded at a more up hole position

(e.g., the surface). For example, the mud pulse telemetry apparatus 1 may be mounted (e.g., top mounted) to the bottom hole assembly (BHA) of a drill string (not shown).

[35] The MP telemetry apparatus 1 includes a power supply 3 and a rotary mud pulser device 2. As described in greater detail below with reference to FIGS. 2A-13, the mud pulser device 2 may include a drive motor configured to be powered by the power supply and a rotating actuator configured to be driven by the drive motor to modulate the flow of fluid through a borehole to encode down hole information.

[36] The down hole information may be any suitable information, including information indicative of the position, status, or other characteristic of a down hole tool (e.g., inclination or drift of the drilling string, azimuth of the drill string, etc.). In some embodiments, the down hole information may be indicative of a down hole ambient condition such pressure, temperature, voltage, vibration, or shock. In some embodiments the down hole information may include sensor data, such a data from a gamma sensor or a nuclear magnetic resonance (NMR) sensor. In some embodiments, the MP telemetry apparatus 1 may receive the information from an external source. In some embodiments, the telemetry apparatus 1 may include one or more on board sensors 4 capable of generating the information. For example, in some embodiments, the sensor 4 may include a dynamics monitoring system of the type described in International Publication No. WO/2015/054432 published April 16, 2015, the entire contents of which are incorporated herein by reference.

[37] In some embodiments, the sensor 4 may be located at portion of the device down hole relative to the mud pulser device 2 and the power supply 3, such that the sensor 4 is closer to one or more down hole tool elements (e.g., a drill), e.g., to more faithfully record a condition of the tool element.

[38] In various embodiments the down hole information may be encoded using any suitable encoding technique, such as the pressure pulse based techniques described in greater detail below. In some embodiments, the down hole information may be encoded using an M-ary encoding technique, e.g., to increase the transmission bit rate in comparison to binary based encoding schemes.

[39] In some embodiments, the down-hole information may be transmitted with a bit rate of at least 0.5 bits per second (bps), 1 bps, 2 bps, 3 bps, 4 bps, 5 bps, or more, e.g., in the range of 0.5- 10 bps or any sub-range thereof.

[48] In various embodiments, some or all of the components of the MP telemetry apparatus

1 may be controlled by control electronics 5. As described in detail herein, the control electronics 5 may be implemented in one or more modules, and may be integrated with one or more components of the MP telemetry apparatus 1 (e.g., the mud pulser device 2, the power supply 3, and the sensor 4).

[41] In some embodiments, the power supply 3 and the drive motor of the mud pulser device

2 are configured to cooperate to drive the rotating actuator with a high level of torque. For example, in some embodiments, the use of an ultracapacitor based rechargeable energy storage and a non-compensated rotary pulser of the type described here (e.g., featuring a robust low friction drive shaft seal), may synergistically allow for the generation of a high level of torque. [42] In some embodiments, the rotating actuator is driven with a torque of at least 100 inch pounds, 200 inch pounds, 300 inch pounds, 400 inch pounds, 500 inch pounds, 750 inch pounds, 1,000 inch pounds, 1,250 inch pounds, 1,500 inch pounds, 1,750 inch pounds, 2,000 inch pounds, or more, e.g., in the range of 100 inch pounds to 2,000 inch pounds or any subrange thereof.

[43] In some embodiments, the torque may be applied to the rotating actuator for a discrete period of time, referred to herein as a pulse or pulse period. Iln some embodiments, the pulse period is at least about 0.1 seconds, 0.2 seconds, 0.3 seconds, 0.4 seconds, 0.5 seconds, 0.7 seconds, 0.8 seconds, 0.9 seconds, 1, second or more, e.g., in the range of 0.1 seconds to 10 second or any sub-range thereof. For example, in some embodiments, the pulse period is in the range of 0.5 seconds to 3 seconds, 0.5 seconds to 5 seconds, or 0.5 seconds to 10 seconds.

[44] In some embodiments, the power supply 3 provides high peak power, e.g., to drive a motor to provide high torque to the rotating actuator for the pulse period. In some

embodiments, the power supply is configured to power the drive motor with a peak delivered power of at least 50 W, 100 W, 250W, 500 W, 1,000 W, 1,250 W, 1,500 W, 1,750 W, 2,000 W or more, e.g., in the range of 10 W to 2,000 W or any sub-range thereof.

[45] In various embodiments, the power supply 3 (along with, e.g., the other operational components of the MP telemetry apparatus 1) is configured to operate under extreme conditions of the type found in down hole drilling operations.

[46] For example, in some embodiments, the power supply 3 includes a high temperature rechargeable energy storage, e.g., of the type described in greater detail herein. The power supply 3 may be configured to operate at temperatures throughout an operating temperature range, wherein the operating temperature range includes 0 degrees Celsius to 125 degrees Celsius, 0 degrees Celsius, 0 degrees Celsius to 210 degrees Celsius, 0 degrees Celsius to 250 degrees Celsius. -40 degrees Celsius to 125 degrees Celsius. -40 degrees Celsius to 150 degrees Celsius, -40 degrees Celsius to 210 degrees Celsius, -40 degrees Celsius to 250 degrees Celsius. In various embodiments, the operating temperature range may include -40 degrees Celsius to 300 degrees Celsius or any sub-range thereof. For example, in some such embodiments, the power supply 3 may be implemented using wide temperature ultracapacitor based energy storage technology of the type described in International PCT Application No. PCT/US14/59971 filed October 9, 2014 and U.S. Provisional Patent Application Nos.

62/108,162 and 62/108,494 filed January 27, 2015, the entire contents of each of which are incorporated herein by reference.

[47] In some embodiments, the power supply 3 (along with, e.g., the other operational components of the MP telemetry apparatus 1) may operate even in the presence of high ambient vibrations. For example, in some embodiments, the power supply 3 is configured to operate in the presence of vibrations of at least 10 G_ms , 20 , 30 G_ms, 50 G_ms 75 G^, 100 G^ or more over a wide range of frequencies (e.g., 50 Hz to 100 Hz). Here G_ms is used in the conventional sense to indicate root mean square acceleration in terms of the gravitation acceleration "G" (9.8 m/s²).

[48 j In some embodiments, the power supply 3 (along with, e.g., the other operational components of the MP telemetry apparatus 1) may operate even in the presence of high ambient mechanical shocks. For example, in some embodiments, the power supply is configured to operate in the presence of mechanical shock of up to 500 G, 1,000 G, 1500 G, 2,000 G or more, e.g., with a shock duration of at least 0.05 milliseconds.

[49] As described in greater detail below, in some embodiments the power supply 3 includes a rechargeable energy storage (e.g., an ultracapacitor based energy storage) that may be coupled to an energy source (e.g., a battery, a down hole generate, a wire line to a top side energy source, combinations thereof, etc.).

[58] In some embodiments, the rechargeable energy storage may be charged by the energy source. For example, in some embodiments, the energy source may be a relatively low rated (e.g., low voltage, low current, low power, etc.) source. The source may be used to charge the energy storage, and the energy storage may in turn be used to provide output with

characteristics that go beyond the rating of the energy source. For example, the source can charge the rechargeable energy storage at relatively low power over a relatively long period of time, and then the rechargeable energy storage may provide a relatively short duration pulse of high power output. For example, in some embodiments, the rechargeable energy storage is configured to provide one or more pulses of output power having a peak power greater than a maximum peak power output of the energy storage.

[51] For example, the rechargeable energy storage may provide a high power pulse to the mud pulser device 2 to drive an electric motor to rotate the rotating actuator with high torque, as discussed above.

[52] In some embodiments, the MP telemetry apparatus 1 is configured to transmit a signal comprising at least one silence period (i.e., a period where the mud pulser device 2 is not operating), and the energy source is configured to at least partially charge the rechargeable energy storage during the at least one silence period.

[53] Further details of ultracapacitor based energy storage devices suitable for use in the power supply 3 are described in detail below in the section entitled "Exemplary Ultracapacitor Based Energy Storage Devices."

[54] Further details of mud pulser devices suitable for use in the mud pulser device 2 are described in detail below in the section entitled "Exemplary Non-Compensated Rotary Pulser." [55] In some embodiments, a mud pulse telemetry kit is provided that includes a power supply module, a rotary mud pulse telemetry device module, and at least one other device such as a linear mud pulse telemetry device module (not shown). The power supply module may be configured to be selectively attachable to each of the rotary mud pulse telemetry device module and the other device. In some embodiments, when attached, the power supply and the rotary mud pulse telemetry device form an embodiment of an MP telemetry device 1 of the type shown in FIG. 1A.

[56] Foln some embodiments, the linear mud pulser device may be a Thunder pulser marketed by Calmena Energy Services of Calgary, Canada. In some embodiments, the linean mud pulser may be bottom mounted (e.g., mounted down hole of the associate power supply module). In some embodiments, the rotary mud pulse telemetry device may be configured to be top mounted on the power supply, e.g., to facilitate wire line recovery.

[57] Kits of this type are advantageous in that they allow the user to select from multiple types of devices (such as telemetry devices) based on the application at hand, while providing a modular power solution. In various embodiments, the power supply module may include any or all of the modular interface control features described below in the section entitled

"Exemplary Ultracapacitor Based Energy Storage Devices," or in International Publication No. WO2014145259 A2, published September 18, 2014, the entire contents of which are incorporated herein by reference.

[58] In some embodiments, a method is disclosed for transmitting information from a drill string positioned at a down hole location in a bore hole to a surface location. The drill string may have a flow passage through which a drilling fluid flows (e.g., as described in greater detail below with reference to FIG. 2A). The method includes the steps of: providing a telemetry apparatus of the type described herein approximate the down hole location and modulating a flow of the drilling fluid using the telemetry apparatus to encode the information to be transmitted to the surface location.

[59] In some embodiments, modulating the flow of the drilling fluid includes causing a power supply and a drive motor to cooperate to drive a rotating actuator with a high torque level, as described herein.

[68] Some embodiments include driving the rotating actuator with a torque of at least 100 inch pounds, 200 inch pounds, 300 inch pounds, 400 inch pounds, 500 inch pounds, 750 inch pounds, 1,000 inch pounds, 1,250 inch pounds, 1,500 inch pounds, 1,750 inch pounds, 2,000 inch pounds, or more, e.g., in the range of 100 inch pounds to 2,000 inch pounds or any subrange thereof.

[61] In some embodiments, the torque may be applied to the rotating actuator for a discrete period of time, referred to herein as a pulse or pulse period. In some embodiments. In some embodiments, the pulse period is at least about 0.1 seconds, 0.2 seconds, 0.3 seconds, 0.4 seconds, 0.5 seconds, 0.7 seconds, 0.8 seconds, 0.9 seconds, 1, second or more, e.g., in the range of 0.1 seconds to 10 second or any sub-range thereof. For example, in some

embodiments, the pulse period is in the range of 0.5 seconds to 3 seconds, 0.5 seconds to 5 seconds, or 0.5 seconds to 10 seconds.

[62] Some embodiment may include providing high peak power, e.g., to drive a motor to provide high torque to the rotating actuator for the pulse period. In some embodiments, the power supply is configured to power the drive motor with a peak delivered power of at least 50 W, 100 W, 250W, 500 W, 1,000 W, 1,250 W, 1,500 W, 1,750 W, 2,000 W or more, e.g., in the range of 50 W to 2,000 W or any sub-range thereof.

[63] In various embodiments, the method may be carried out under extreme conditions of the type found in down hole drilling operations.

[64] For example, in some embodiments, the telemetry device may be operated at temperatures throughout an operating temperature range, wherein the operating temperature range includes 0 degrees Celsius to 125 degrees Celsius, 0 degrees Celsius, 0 degrees Celsius to 210 degrees Celsius, 0 degrees Celsius to 250 degrees Celsius. -40 degrees Celsius to 125 degrees Celsius. -40 degrees Celsius to 150 degrees Celsius, -40 degrees Celsius to 210 degrees Celsius, -40 degrees Celsius to 250 degrees Celsius. In various embodiments, the operating temperature range may include -40 degrees Celsius to 300 degrees Celsius or any sub-range thereof.

[65] In some embodiments, the telemetry device may be operated in the presence of high ambient vibrations such as vibrations of at least 10 G^_s , 20 G^_s , 30 G^ 50 G_nns 75 G^ 100 Gi_ms, or more, e.g., over a wide range of frequencies (e.g., 50 Hz to 100 Hz). Here G_ms is used in the conventional sense to indicate root mean square acceleration in terms of the gravitation acceleration "G" (9.8 m/s²).

[66] In some embodiments, the telemetry device may be operated in the presence of high ambient shock, in some embodiments, mechanical shock of up to 500 G, 1,000 G, 1500 G, 2,000 G or more, e.g., with a shock duration of at least 0.05 milliseconds.

[67] Some embodiments include adding loss circulation material (LCM) to the drilling fluid. In some embodiments, modulating a flow of the drilling fluid comprises modulating the flow of drilling fluid containing the LCM. In some embodiments, the use of a high torque rotary pulser (especially a non-compensated pulser rotary pulse as described) allows for suitable operation of the telemetry apparatus even in the presence of LCM that would inhibit or degrade the operation of conventional mud pulse telemetry devices.

[68] For example, in some embodiments, the telemetry device operates even in the presence of LCM that has a median particle size of at least 500 μηι, at least 750 μηι, at least 1,000 μηι, at least 1,500 μηι, at least 2,000 μηι or more, e.g., in the range of 1-2,000 μηι or any sub-range thereof.

[69] In some embodiments, the telemetry device operates even in the presence of LCM that is added to the drilling fluid at a rate of at least 1 pound per fluid barrel (p/bbl - equivalent to 3.80401357 kg /m³), at least 2 p/bbl, at least 5 p/bbl, at least 10 p/bbl, at least 20 p/bbl, at least 30 p/bbl, or more, e.g., in the range of 1 to 100 p/bbl or any sub-range thereof.

[70] In some embodiments, the telemetry device operates even in the presence of LCM that has a specific gravity of at least 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 2.0, 25, or more, e.g., in the range of 1.0 to 3.0 or any sub-range thereof. [71] In various embodiments any LCM known in the art may be used including fibrous (cedar bark, shredded cane stalks, mineral fiber and hair), flaky material (mica flakes and pieces of plastic or cellophane sheeting), granular material (ground and sized limestone or marble, wood, nut hulls, Formica, corncobs and cotton hulls), or combinations thereof.

[72] Accordingly, several examples of improved mud pulse telemetry techniques have been described, especially those suitable for use in applications where LCM is used in the drilling fluid. In the following, additional detail is provided for embodiments of mud pulsers

(especially non-compensated rotary mud pulsers) and power systems (especially ultracapacitor based supply systems) that may be advantageously used, alone or in any suitable combination, in mud pulse telemetry devices, systems, kits, and methods as described herein.

[73] Exemplary Non-Compensated Rotary Pulser

[74] With reference to FIG. 2A, a bore hole drilling operation including a mud pulse telemetry system 10 in accordance with the current disclosure is shown. Drill bit 11 attached to a down hole end of a drill string 12 drills a bore hole 14 into a formation 16. The drill string 12 is conventional and is comprised of several sections of pipe coupled together. The drill string 12 can be rotated at the surface using conventional equipment to drill the bore hole 14 or the drill string can include down hole motor 18 for rotating the drill bit 10, thereby drilling the bore hole. The drilling operation further includes a typical drilling fluid or drilling mud system having a drilling fluid pump 20 which pumps drilling fluid 22 down a flow passage 24 of the drill string 12 where it then flows outward from the drill bit 10 into the annulus 26 between the outer surface of the drilling string and the bore hole 14. The drilling fluid 22 then continues to flow upward through the annulus 26 to the surface where it is cleaned by a drilling fluid cleaning system (not shown) and then recirculated back into the flow passage 24. The mud pulse telemetry system 10 in accordance with the current invention is shown positioned at a down hole location 30 within the flow passage 24 of the drill string.

[75] In some embodiments, loss circulation material LCM may be added to the drilling fluid 22, e.g., to reduce or eliminate loss of drilling fluid into the geological formation,

[76] With reference to FIG. 2B , a basic system diagram of the mud pulse telemetry system 10 is shown. The telemetry system 10 includes sensor package 32 for measuring down hole parameters, a data encoder 34, a power supply 36, and a pulser 38. In some embodiments , the power supply 36 may include, a battery, a generator (e.g., a turbine), a wire line source, or combinations thereof.

[77] In some embodiments, the power supply 36 may include or be operatively coupled to a rechargeable energy storage, e.g., an ultracapacitor based rechargeable energy storage as described herein. In some embodiments, the power supply 36 may be omitted, and an external power supply module operatively coupled to the telemetry system 10.

[78] The pulser 38 comprises a controller 40, which may be a microprocessor, motor driving circuitry 42, a motor 44, such as a reversible brushless DC motor that operates at, e.g., a minimum of 1000 RMP, a reduction gear box 46 that can provide a speed reduction, e.g., of at least about 200: 1 , 300: 1 ; 400: 1 : 500: 1 or more, e.g., in the range of 200: 1 to 5,000:1 or any subrange thereof. For example, in some embodiments, the reduction gear box comprises a epicyclic or planetary type gear box.

[7 j The pulser 38 further includes a stator 48, a rotor 50, a drive shaft 52 directly coupling the output of the motor to the rotor, an angular position encoder 54, and a drilling fluid pressure sensor 56.

[80] Sensor package 32 can include a single sensor or multiple sensors for measuring various down hole parameters such as but not limited to inclination or drift of the drilling string, azimuth of the drill string, pressure, temperature, voltage, and shock. The sensor package 32 receives or measures information 58 useful in connection with the drilling operation and sends output signals 60 to the data encoder 34. The data encoder 34 receives the output signals 60 and generates a digital code 62 that is transmitted to the controller 40. The controller 40 processes the digital code and generates command signals 64 to the motor driving circuitry 42. The motor driving circuitry 42 operates the motor 44 in accordance with the command signals to rotate the rotor 50 to generate pressure pulses 68 in the drilling fluid 22. The pressure pulses 68 are sensed by a sensor 70 positioned at the surface and are decoded and processed by a data acquisition system 72. The angular position encoder 54 suitable for high temperature applications is coupled to the output of the motor 44. The angular position encoder 54 sends signal 55 to the controller 40 containing information of the angular position of the rotor 50, which may also be used by the controller in generating command signals 64. The drilling fluid pressure sensor 56 measures the pressure of the drilling fluid 22 within the flow passage 24 and transmits signal 57 to the controller 40 containing information pertaining to the pressure of the drilling fluid.

[81] In some embodiments, the sensor package 32 may be omitted, e.g., in embodiments where the telemetry system 10 is operatively coupled to one or more external sensor modules.

[82] Further, the mud pulse telemetry system 10 may include a pressure pulse generator 28 positioned at the surface for generating pulses 29 within the drilling fluid 22. The pressure pulse 29 may be encoded with operation information and are received by drilling fluid pressure sensor 56 and transmitted to the controller 40. The operation information may be used by the controller 40 in generating command signals 64.

[83] With reference to FIG. 3 , a partial schematic diagram of the mechanical arrangement of the pulser 38 is shown. The pulser 38 is shown positioned with the flow passage 24 of the drill string 12 at the down hole location 30 such that the drilling fluid 22 is caused to flow across the pulser. The pulser 38 can be fixedly attached to the drilling string 12 or removably attached to the drilling string through the use of a conventional hanger sleeve (not shown) to facilitate wire line placement and retrieval of the pulser. A wire line is removable attachable to a spear point 75 forming part of the pulser 38. [84] The rotor 50 is preferably positioned upstream of the stator 48 and is driven by a drive train positioned within the pulser body 74. The rotor is connected to a drive shaft 52 which is supported by a bearing assembly 76. In some embodiments, the bearing assembly may include a bi-directional thrust bearing assembly.

[85] The drive shaft is connected to a reduction gear box 46 which is coupled to the output of the motor 44. The motor 44, the reduction gear box 46 and a portion of the drive shaft 52 is positioned within an internal housing 78 defined by the pulser body 74. A seal 80 is positioned about the drive shaft 52 such that the drive shaft extends axially through the seal and such that seal seals the internal housing 78. The internal housing is gas filled, preferably with an inert gas and at atmospheric pressure.

[86] The pressure sensor 56 is received by the pulser body 74 such that the pressure of the drilling fluid 22 within the flow passage 24 may be measured. Additionally, the pulser body 74 houses the controller 40, the motor driving circuit 42, and the sensor package 32.

[87] With reference to FIGS . 4-13 an embodiment of the telemetry system 10 is shown positioned at a down hole location 30 within a the flow passage 24 of the drilling string 12. The pulser 38 is of an elongated cylindrical shape of a dimension permitting the placement of the pulser within the flow passage 24 with out unduly restricting the flow of drilling fluid 22 through the flow passage 24. The pulser 38 includes a pulser body 74 that can be of a unitary construction or can be of a plurality of separate body members coupled together as shown. As previously mentioned, the pulser body 74 can be fixedly mounted to the drill string 12 or removably mounted to the drill string through the use of a conventional hanger sleeve 82 which is attached to the drill string. The pulser includes at its upstream most end a spear point 75 which is engagable with a wire line for placement and retrieval of the pulser 38.

[88] In some embodiments, the telemetry system 10 has an elongated probe shaped form factor with a maximum radial outer diameter of less than about 4 inches, less than about 3 inches, less than about 2.5 inches, or less, e.g., in the range of 2 inches to 6 inches or any subrange thereof.

[89] A rotor 50 is positioned within the flow passage 24 coaxially with the drill string 12 and preferably upstream of a stator 48. With additional reference to FIGS. 10 and 11 , which are transverse cross-section views of the pulser 38 taken through the rotor 50, the rotor includes a plurality of lobes 100 extending radially from a center portion 102 and the stator includes a plurality of channels 104 equal to the number of lobes 100 through which the drilling fluid 22 is directed. The rotor 50 is rotatable with respect to the stator 48 such that the lobs 100 of the rotor are positioned to at least partially block the drilling fluid 22 from flowing through the channels 104 of the stator as shown in FIG. 11 and is rotatable to at least partially reduce the blockage as shown in FIG. 10.

[90] The rotor 50 is connected to a drive shaft 52 which extends axially through the stator 48 and the pulser body 74. The drive shaft 52 is support at an upstream end of the pulser body 74 by a bushing 85 and at a downstream end by a bearing 86 and is coupled to a reduction gear box 46, which is in turn coupled to the output of a motor 44, as shown in FIG. 5. The motor 44, the reduction gear box 46 and a portion of the drive shaft 52 is positioned in an internal housing 78 defined by the pulser body 74. The internal housing 78 is filled with gas, such as air or preferably an inert gas and at or near atmospheric pressure. A seal 80, which will be described in further detail below, is positioned about the drive shaft 52 such that the drive shaft extends axially through the seal and such that the seal seals the internal housing 78. A seal housing 83 defined by the pulser body 74 receives the seal 80.

[91] In some embodiments, one or more elements of the system 10 that are subject to high levels of wear or erosion (e.g., due to drilling fluid flow) may be constructed from wear resistant material, e.g., carbide material. For example, in some embodiments, each of the rotor 50 and the stator 48 may be constructed as a unitary body, e.g., of carbide material.

[92] The pulser 38 includes a fluid pressure sensor 56 for measuring the pressure of the drilling fluid 22 within the flow passage 24. The fluid pressure sensor 56 can comprises a piston 110 received within pressurized oil filled bore 112 defined by the pulser body 74. The piston 110 has an outward facing surface 114 which is contactable by the drilling fluid 22. The piston 110 is caused to displaced inward or outward depending upon the drilling fluid pressure exerted upon the outward facing surface. The inward and outward displacement of the piston 110 is related to the pressure differential between the pressure of the drilling fluid 22 and the pressure of the oil within the bore 112. An inward displacement of the piston 110 compresses the oil and increases the pressure within the bore 112. Similarly, an outward displacement of the piston 110 decompresses the oil and decreases the pressure within the bore 112. The pressure within the bore is measured by a transducer 116 that generates a pressure signal 57 and transmits the pressure signal to a controller 40.

[93] An angular position encoder 54 suitable for high temperature applications is coupled to the output of the gear box 46. The angular position of the rotor attached to the shaft 52 is defined by the angular position encoder 54, and the hall sensors built into the motor 44 which sends signal 55 to the controller 40 containing information of the angular position of the rotor 50, which may also be used by the controller in generating command signals 64. The angular position encoder can be that of a hall effect sensor 94 positioned about the drive shaft 52 and a magnet 96 secured to the drive shaft. The angular position encoder 54 defines a known angular point of the draft shaft 52 which in turn results in a known position of the rotor 50 attached to the drive shaft. The telemetry system 10 uses this point as a start reference, the drive shaft 52 is rotated x number of counts in a direction to at least partially block or at least partially reduce the blockage the flow passage 24 by counting the pulses generated by the angular position encoder.

[94] FIG. 15 shows an exemplary embodiment of the angular position encoder 54 that includes four magnets 96 secured about the drive shaft 52 (not shown). A nonmagnetic annular collar 1501 receives the magnets 96 (e.g., neodymium type magnets) at four locations spaced at different angular locations. The collar 1501 is secured to the driveshaft, e.g., using set screws 1502. The four magnets allow for the drive shaft angular position to be detected with up to a ¼ turn accuracy. However, in other embodiments any other suitable number of magnets 96 may be used. In some embodiments multiple hall sensors 94 may be used, e.g., one sensor for each respective one of the magnets 96.

[95] As shown in FIG. 6 the pulser body 74 defines an electronics housing 90 which is positioned therein the various electronic assemblies of the telemetry system 10, such as but not limited to the controller 40, a motor driving circuit 42, and a sensor package 32. The sensor package 32 can include various sensors such as but not limited to a drift or inclination sensor, an azimuth sensor, a temperature sensor, a pressure sensor and a shock sensor.

[96] The pulser 38 further includes a mid centralizer 92 an end view thereof is shown in FIG. 7a and a longitudinal cross-section is shown in FIG. 7b. The mid centralizer includes a plurality of centralizing blades 94 which extend from the body 96 thereof. The centralizing blades 94 contact the inner surface of the drill string 12 and centralize the pulser body 74 within the flow passage 24. A power supply 36, such as a battery back, is also provided and is shown in FIG. 8. Further, a bottom centralizer 98, shown in FIGS. 9a and 9b, is included and acts to centralize the bottom of the pulser 38 within the flow passage 24. As in the mid-centralizer 92, the bottom centralizer 98 includes a plurality of centralizing blades 99 which contact the inner surface of the drill string 12.

In some embodiments, the telemetry system 10 may include a bypass flow path (not shown), e.g., for diversion of the flow of drilling fluid when the drilling fluid exceeds a threshold flow rate (e.g., above 300 gallons per minute (gpm), 400 gpm, 500 gpm, 600 gpm, 700 gpm, 800 gpm, 900 gpm or 1 ,000 gpm). In various embodiments, one or more flow diverters may be used, including, e.g., a flow control valve, a Venturi tube device, a vaned passage, and combinations thereof.

[97] Now with reference to FIGS. 12 and 13 , a detailed discussion of the seal 80 will be had.

FIG. 12 is an enlarged longitudinal cross section of the seal 80 and FIG. 13 is a partial exploded view of the seal. The seal 80 provides an uncompensated drive train for the pulser 38 that simplifies and reduces manufacturing and maintenance costs of the pulser. Heretofore, pulsers have had a compensated drive train where all or at least part of the drive train is positioned within pressurized oil filled housing. This was required to eliminate a high pressure differential across a seal where a driving shaft of the drive train would exit the housing into the drilling fluid to create either a rotating action or a reciprocating action to drive an actuator such as a rotor or a hydraulic valve. Without the compensation and under a high pressure differential there is a high amount of friction or seal drag across the seal requiring a large torque to drive the shaft making battery operated devices undesirable. Further under a high pressure differential, when the shaft has been broken free to move it is very prone to leakage. [98] The seal 80 in accordance with the present invention provides the pulser 38 with an uncompensated drive train that overcomes all of the drawbacks of a compensated drive train and which efficiently operates under a high pressure differential. The seal 80 is received within a seal housing 83 defined by the pulser body 74 as shown. The seal 80 encompasses the drive shaft 52 which extends axially through the seal. The seal 80 comprises of a unique stacked array of a plurality of seal elements 82 held by a plurality of seal holders 84 and seal washers 86 positioned intermediate of adjacent seal holders 84. Preferably, the seal elements are of a polypack or a poly-O type seal. The seal elements 82 are positioned about the drive shaft 52 and retained in position by the seal holders 84. Each seal holder 84 positions and retains two seal elements 82, one of the seal elements 82a being retained juxtaposed the surface of the drive shaft 52 and the second of the seal elements 82b being retained juxtaposed the surface of the seal housing 83. The first seal element 82a is of a diameter less than that of the second seal element 82b. Each seal holder 84 is generally cylindrical in shape and includes first shoulder 86 of a first diameter, a first lip 88 extending upwardly from the outer circumference of the first shoulder, a second shoulder 89 of a second diameter that is greater then the diameter of the first shoulder, and a second lip 90 extending from the inner circumference of the second shoulder in a direction opposite of the first lip.

[99] In a preferred arrangement, the seal holders 84 each retaining two seal elements 82 are positioned about the drive shaft 52 such that seal elements 82a and 82b are arranged in an alternating pattern. As shown, three seal holders 84 each retaining two seal elements 82 for a total of six seal elements are positioned about the drive shaft 52 and within the seal housing 83 in a stacked arrangement. A seal washer 86 is positioned between the first and second seal holders, a second seal washer is positioned between the second and third seal holders, and a third seal washer is positioned between the third seal holder and a bottom edge 92 of the seal housing. A bushing 85 retained by the pulser body 74 is positioned above the seal 80 and retains the seal within the seal housing 83.

[100] FIGs. 14A-14C show an alternate embodiment of the seal 80 featuring a cartridge configuration. FIG. 14A is a perspective view. FIG. 14B is a side cross sectional view. FIG. 14C is an exploded perspective view. As shown, alternate seal 1400 includes a plurality of seal elements 1401 and a plurality of seal carriers 1402 holding said plurality of seal elements 1401. The plurality of seal elements 1401 includes a group of outer seal elements 1401a and a group of inner seal elements, 1401b. Each outer seal element 1401a is maintained by a respective seal carrier 1402a in a position juxtaposed against a surface of a pulser body (not shown) disposed radically about the seal 1400. Each inner seal element 1401b is maintained by the seal carrier 1402b in a position juxtaposed against a radial surface of the drive shaft (not shown). The seal elements 1401a/1401b are each held by a respective one of the plurality of seal carriers 1402a/1402b such that the group of outer seal elements 1401a and the group of inner seal elements 1401b are arranged in an alternating pattern. For example, as shown, in order from front to back outer seal element 1401a, inner seal element 1401b, outer seal element 1401a, inner seal element 1401b, and outer seal element 1401a.

[301] As shown, the seal 1400 comprises a seal cartridge 1403 defining a longitudinally extending bore 1404 configured to receive the drive shaft (not shown). The seal cartridge 1403 is segmented and includes a front end cartridge segment 1405 configured to be positioned distal the internal housing (as shown, toward the left side of the figure) and a seal carrier 1402a for at least one of the outer seal elements 1401a. The cartridge 1403 also includes a back end cartridge segment 1406 configured to be positioned proximal the internal housing (as shown, towards the right side of the figure) and comprising a seal carrier 1402a for at least one of the outer seal elements 1401a. The cartridge 1403 further includes one or more (one is shown) intermediate cartridge segments 1407 disposed in series between the front end cartridge segment 1405 and the back end cartridge segment 1406. Each intermediate cartridge segments comprises a seal carrier 1402a for at least one of the outer seal elements 1401a. The cartridge segments 1405, 1406, 1407 fit together such that a respective seal carrier 1402b for each inner seal element 1401b is formed by a connection of an intermediate segment 1407 with one of another intermediate segment 1407 (not shown), the front end segment 1405, and the back end segment 1406.

[182] In various embodiments, the cartridge segments 1404, 1405, 1406 may be secured together using any suitable technique including, e.g., interference fit, adhesives, welding, soldering, mechanical attachment (e.g., screws, fasteners , keying mechanisms, etc.).

[103] In various embodiments, any suitable number of intermediate cartridge segments may be used, e.g., to increase the redundancy of the seal 1400. For example, in some embodiments, three or more intermediate cartridge segments 1407 may be used such that the group of outer seal elements 1401a includes at least five seal elements, an the group of inner seal elements 1401b includes at least four seal elements.

[184] In some embodiments, the group of inner seal elements 1401b includes at least one polymeric wiper seal positioned distal to the internal housing and at least one spring loaded seal positioned more proximal the internal housing than the polymeric wiper seal. In some embodiments, the group of outer seal elements 1401a includes one or more t-shaped seal. In some embodiments, at least one of the inner or outer seal elements 1401 includes a polypak or poly-O type seal element.

[185] In some embodiments, the seal 1400 may eliminate leakage of liquids (e.g., drilling fluid) across the seal 1400, even under extreme down hole conditions (e.g., the temperature, shock, and vibration conditions set forth herein and/or high ambient pressure of e.g., up to 1 ,000 pounds per square inch (PSI), 5,000 PSI, 10,000 PSI, 15,000 PSI, 20, 0000 PSI, 25,000 PSI, or more.

[ίθ6] As can now be understood, in operation, the mud pulse telemetry system 10 is designed to function in agreement with a process know as "making a connection" in a drilling operation. The process of making a connection involves the coupling of an additional pipe section to the drilling string as a bore hole is drilled deeper into a formation. To facilitate the coupling of an additional pipe section, the drilling is stopped and the drilling fluid pump 20 is turned off to stop pumping drilling fluid 12 through the drill string 12 and to reduce drilling fluid pressure within the drilling string to a static pressure which is less then the pressure of the drilling fluid during pump on operation. The mud pulse telemetry system 10 makes use of this intermittent cessation of drilling to take measurements of down hole parameters which are useful for the drilling operation. The cessation of drilling is detected by measuring the pressure of the drilling fluid 22 within the flow passage 24. Once a predetermined drop of drilling fluid pressure, the telemetry system 10 determines it is time to take down hole measurements at a time after the pressure drop is detection. Upon a detection of a predetermined rise of drilling fluid pressure, the telemetry system 10 begins to operate the pulser 38 at a time after the pressure rise is detected to generate encoded pressure pulses within the drilling fluid.

[107] In some embodiments, the telemetry system 10 may be top mounted on a drill string (e.g., on a bottom hole assembly). In some embodiments , the system 10 may terminate at its down hole end with a stinger (e.g., as shown in FIG. 1A), suitable for connection to a mule shoe receptacle, e.g., mounted on universal bottom hole orientation subassembly.

[108] FIG. 16 shows an exemplary stinger /mule shoe connection. The telemetry system 10 (not fully shown) terminates at is down hole end with a stinger 1601. The stinger 1601 is received by a mule shoe 1602. In some embodiments, a wear cuff 1605 may be provided at the location where the stinger 1601 mates with the mule shoe 1602. In some embodiments the wear cuff 1605 may be constructed of a wear resistant material such as a carbide material. In some embodiments, the wear cuff 1605 may be a replaceable element (e.g., configured to be easily replaced without the need for disassembling or modifying the system 10).

[109] In some embodiments, the stinger 1601 may include facilities for fastening the stinger 1601 to the mule shoe 1602. For example, the stinger 1601 (and/or the wear cuff 1605) may be provided with a set of screw holes matching a corresponding set on the mule shoe 1602, allowing screws to be used to fasten the stinger 1601 and mule shoe 1602. In some

embodiments, the fasteners may be configured to allow disconnection of the stinger 1601 and mule shoe 1602, e.g., during an emergency retrieval process. For example, the stinger 1601 and mule shoe 1602 may be attached using shear screws having a shear force calibrated such that the screws withstand down hole conditions during normal operation, but shear off during a retrieval operation (e.g., in response to the force from a wire line retrieval).

[110] As noted above, in some embodiments the mud pulse telemetry system 10 is designed to be retrievable from down hole (e.g., be wire line) in the event that down hole elements of the drill string become irretrievable. In some such embodiments, the mud pulse telemetry system 10 may include one or more centralization features (e.g., centralizing blades 94 contact the inner surface of the drill string 12 and centralize the pulser body 74 within the flow passage 24). In order to facilitate retrieval, a separator device may be provided to separate the centralization features from the system 10. For example, referring to FIG. 17, a fin cutter 1701 may be provided. The fin cutter 1701 includes an annular body 1702 configured to be disposed about the pulser body 74 (not shown), with an outer diameter that is lass than that of the centralizing blades 94 (sometimes referred to as "fins"). The fin cutter 1701 includes a cutting edge 1703. During retrieval of the telemetry system 10, the fin cutter 1701 moves relative to and along the outside of pulser body 74, and cuts away the centralizing blades 94 (which may be made of a cuttable, e.g., plastic or elastomeric material). In some embodiments, all or a portion of the fin cutter 1701 (e.g., the cutting edge), may be made of a wear resistant material such a carbide material. In some embodiments , the all or a portion of the fin cutter 1701 (e.g., the cutting edge) may be a replaceable element (e.g., configured to be easily replaced without the need for disassembling or modifying the system 10).

[ill] In various embodiments other suitable types of separator devices may be used to remove centralization features to facilitate retrieval of the telemetry system 10. In various embodiments the separator devices may be actuated by any suitable technique including mechanical, electrical, pneumatic, or other techniques.

[112] In various embodiments, elements of the telemetry system 10 that are subject to high levels of wear (e.g., points of weight bearing attachment) or erosion (e.g., due to circulating drilling fluid flow) during use may be implemented as wear resistant elements, e.g., made from carbide material. Exemplary replaceable elements may include wear cuff 1605, rotor 50, and stator 48.

[113] In various embodiments, elements of the telemetry system 10 that are subject to high levels of wear (e.g., points of weight bearing attachment) or erosion (e.g., due to circulating drilling fluid flow) during use may be implemented as a replaceable element (e.g., configured to be easily replaced without the need for disassembling or modifying the system 10).

Exemplary replaceable elements may include the centralizing blades 94, fin cutter 1701 , and wear cuff 1605.

[114] In one aspect, the telemetry system 10 can operate in either a short survey mode and a long survey mode. In the short survey mode one only down hole parameter information, such as inclination, is be transmitted to the surface. In the long survey mode multiple sets of information pertaining to various down hole parameters, such as inclination, azimuth, temperature, shock, pressure or battery voltage, is transmitted to the surface. The telemetry system 10 may also operate in a combined short and long survey mode where the telemetry system operates in the short survey mode and then in the long survey mode. The telemetry system 10 may operate in the short survey mode for a number of information transmission and then switch to the long survey mode of another number of information transmission and then back to the short survey mode.

[115] The pressure pulses 68 are sensed by a sensor 70 positioned at the surface and are decoded and processed by a data acquisition system 72. The data acquisition system 72 displays pressure data in a time vs. pressure chart and automatically decodes the survey data and displays the drift (inclination of the drill string) corresponding to time and date in a table. The drill operator then can enter the depth of the drilling string if reading is acceptable. Each time a depth is entered corresponding to a drift measurement, a point is plotted on a depth vs. drift graph which is displayed to the drill operator to use in making any necessary drilling changes.

[116] In various embodiments, any other suitable graphical data display and/or user interface may be provided based on, e.g., the drilling application at hand.

[117] Exemplary Ultracapacitor Based Energy Storage Devices

[118]

[119] In certain embodiments, the power supply for MP telemetry devices and systems disclosed herein may include power converters, particularly high efficiency power converters, e.g., switched-mode power supplies. In some embodiments, the power converter is a switched- mode power converter, which may be regulated by feedback control. Examples of power converters include inductor-based converters, for example, buck, boost, buck-boost, boost- buck, Cuk, forward, flyback, or variants or the like as well as inductorless converters such as switched capacitor converters. The power converters disclosed herein are compatible with a combination of requirements of high power (e.g., high torque) MP telemetry include high average power, high pulse (or peak) power, high temperature tolerance (i.e., up to about 200°C, 210 °C, 250 °C, or even 300 °C), and tolerance of other downhole conditions (e.g., shock, vibration, pressure, and rotational forces). The power converters disclosed herein meet these requirements while maintaining high overall operational efficiency levels, particularly efficiencies of at least 50%, at least 70%, at least 80%, at least 90%, or at least 95%.

[128] Referring to FIG. 18, The MP telemetry devices and systems disclosed herein may include high temperature rechargeable energy storage devices (HTRESDs), e.g., including ultracapacitors, that operate over a range of environmental conditions found in a downhole environment. The HTRESDs disclosed herein operate at temperatures up to about 200 °C, 210 °C, 225 °C, 250 °C , and even higher temperatures may be attained under certain conditions. Additionally, the HTRESDs disclosed herein operate at temperatures at the other end of the temperature range encountered in the drilling environment, e.g., at temperatures down to about - 40 °C and below, and all temperatures in between these lower and upper temperature bounds, or any sub-range thereof.

[ill] The HTRESDs disclosed herein are capable of delivering instantaneous power to downhole telemetry devices and/or other instrumentation in these extreme environmental conditions. HTRESDs suitable fore use with MP telemetry systems described herein are disclosed in PCT Publication Nos. WO2013/009720 published January 17, 2013 and

WO2013/126915 published August 29, 2013, which are incorporated herein by reference in their entirety. In addition, suitable HTRESDs, as well as related power systems and manufacturing processes, are disclosed in US Patent Publication Nos. US2013/0026978, US2013/0029215, US2013/0045157, US2013/0044405, US2013/0271066, US2013/0143108, and US2013/0141840 (filing dates provided in Table 2 below); PCT Publication No.

WO/2014/145259 published September 18, 2014; International Patent No. PCT/US14/59971, filed October 9, 2014; and U.S. Provisional Patent No. 62/081,694, filed November 19, 2014, the entire contents of each of which are incorporated herein by reference.

[122] Ultracapacitor based HTRESDs of the type described in the foregoing references may, for example, operate at temperatures as low as -40 degrees Celsius and high as 250 degrees Celsius (and in any sub-range therebetween) or more for 10,000 charge/discharge cycles and/or over 100 hours or more at a voltage of 0.5 V or more. In some embodiments the ultracapacitors provide this performance while exhibiting and increase in equivalent series resistance (ESR) of less than 100%, e.g. less than about 85% and a decrease in capacitance of less than about 10%. In some embodiments, such ultracapacitors may have a volumetric capacitance of about 5 Farad per liter (F/L), 6 F/L, 7 F/L, 8 F/L, 8 F/L, 10 F/L or more, e.g., in the range of about 1 to about 10 F/L or any sub-range thereof.

[123] In some embodiments, ultracapacitors of the types described herein may exhibit any of: a high volumetric energy density (e.g., exceeding 0.25 Wh/L, 0.5 Wh/L, 1 Wh/L, 2 Wh/L, 3 Wh/L, 4 Wh/L, 5 Wh/L, 6 Wh/L, 7 Wh/L, 8 Wh/L, 9 Wh/L, 10 Wh/L, 11 Wh/L, 12 Wh/L, 15 Wh/L, 18 Wh/L, 20 Wh/L, or more), a high gravimetric energy density (e.g., exceeding 5 Wh/kg, 6 Wh/kg, 7 Wh/kg, 8 Wh/kg, 9 Wh/kg, 10 Wh/kg, 11 Wh/kg, 12 Wh/kg, 15 Wh/kg, 18 Wh/kg, or more), a high volumetric power density (e.g., exceeding 30 kW/L, 40 kW/L, 50 kW/L, 60 kW/L, 70 kW/L, 80 kW/L, 90 kW/L, 100 kW/L, 110 kW/L, 120 kW/L, or more), a high gravimetric power density (e.g., exceeding 30 kW/kg, 40 kW/kg, 50 kW/kg, 60 kW/kg, 70 kW/kg, 80 kW/kg, 90 kW/kg, 100 kW/kg, 110 kW/kg, 120 kW/kg or more), and combinations thereof. In some embodiments, ultracapacitors of the types described herein demonstrate high performance as indicated by the product of energy density and power density, e.g., exceeding 300 Wh-kW/L², 500 Wh-kW/L², 700 Wh-kW/L², or more.

[124] For example, the ultracapacitors disclosed herein are capable of maintaining their performance over a long period of time, e.g., hundreds of thousands, or even millions of charge/discharge cycles. Table 1 below shows the performance of exemplary cells of the type described herein. For the purposes of Table 1, cell lifetime is defined as the number of cycles required before the cell exhibits a reduction in discharge energy of 5% or more or an increase in equivalent series resistance (ESR) of the cell of 25% or more.

[125] Table 1

[126] Exemplary Ultracapacitor Performance Data

[127] As trade-offs may be made among various demands of the ultracapacitor (for example, voltage and temperature) performance ratings for the ultracapacitor may be managed (for example, a rate of increase for ESR, capacitance) may be adjusted to accommodate a particular need. Note that in reference to the foregoing, "performance ratings" is given a generally conventional definition, which is with regard to values for parameters describing conditions of operation.

[128] Applicants have found that HTRES devices featuring ultracapacitors of the type described in the references incorporated herein may also be suitable for the extreme vibrations and mechanical shocks found in the downhole environments.

[129] In some embodiments, the HTRES device is configured to operate in the presence of vibrations of up to maximum vibration rating for an operational period. In some embodiments the operational period is at least 100 hours, and the maximum vibration rating is at least 1 Grms,

2 Grms, 5 Grms, 10 Grms, 20 Grms, 30 Grms, 40 Grms, 50 Grms, 60 Grms, 70 G_m!, 80 G_m!, 90 Grms , 100

Grms, or more, e.g., in the range of 1 to 100 Grms or any sub-range thereof. In some

embodiments the operational period is at least 500 hours, and the maximum vibration rating is at least 1 Gnns, 2 Grms, 5 Grms, 10 Grms, 20 Grms, 30 Grms, 40 Grms, 50 Grms, 60 Grms, 70 Grms, 80

Grms, 90 Grms , 100 Grms, or more, e.g., in the range of 1 to 100 Grms or any sub-range thereof. In some embodiments the operational period is at least 1,000 hours, and the maximum vibration rating lS at least 1 Grms, 2 Grms, 5 Grms, 10 Grms, 20 Grms, 30 Grms, 40 Grms, 50 Grms, 60 Grms, 70

Grms, 80 Grms, 90 Grms , 100 Grms, or more, e.g., in the range of 1 to 100 Grms or any sub-range thereof. In some embodiments the operational period is at least 5,000 hours, and the maximum

Vibration rating lS at least 1 Grms, 2 Grms, 5 Grms, 10 Grms, 20 Grms, 30 Grms, 40 Grms, 50 Grms, 60

Grms, 70 Grms, 80 Grms, 90 Grms ,100 Grms, or more, e.g., in the range of 1 to 100 Grms or any subrange thereof. In each case this vibration performance may be obtained over a wide range of vibration frequency, e.g., 50 Hz to 500 Hz.

[130] In some embodiments, the HTRES device is configured to operate in the presence of shocks up to a maximum shock rating. In some embodiments, the shock rating may be at least 10 G, 20 G, 30 G, 50 G, 100 G, 200, G, 300 G, 400 G, 500 G, or more, e.g., in the range of 10 G to 1 ,000 G or any sub-range thereof.

[131] In various embodiments, MP telemetry systems of the type described herein may be configured to have similar operational temperature, vibration, and shock ranges.

[132] Additional embodiments of HTRESDs include, without limitation, chemical batteries, aluminum electrolytic capacitors, tantalum capacitors, ceramic and metal film capacitors, hybrid capacitors magnetic energy storage, for instance, air core or high temperature core material inductors. Other types of HTRESDs that may also be suitable include, for instance, mechanical energy storage devices, such as fly wheels, spring systems, spring-mass systems, mass systems, thermal capacity systems (for instance those based on high thermal capacity liquids or solids or phase change materials), hydraulic or pneumatic systems.

[133] One example is the high temperature hybrid capacitor available from Evans Capacitor Company Providence, RI USA part number HC2D060122 DSCC10004-16 rated for 125 °C. Another example is the high temperature tantalum capacitor available from Evans Capacitor Company Providence, RI USA part number HC2D050152HT rated to 200°C. Yet another example is an aluminum electrolytic capacitor available from EPCOS Munich, Germany part number B41691A8107Q7, which is rated to 150 °C. Yet another example is the inductor available from Panasonic Tokyo, Japan part number ETQ-P5M470YFM rated for 150 °C. Additional embodiments are available from Saft, Bagnolet, France (part number Li-ion VL 32600-125) operating up to 125 °C with 30 charge-discharge cycles, as well as a lithium-ion battery (experimental) operable up to about 250 °C Celsius, and in experimental phase with Solid Energy of Watertown, Massachusetts. In certain embodiments of the devices and systems disclosed herein, the HTRESD is a high temperature ultracapacitor. However, this is not limiting of technologies that may be included in the energy storage of the MP telemetry devices and systems disclosed herein.

[134] Alternatively or additionally, the power supply for the MP telemetry devices and systems disclosed herein may include one or more batteries, particularly down hole-compatible batteries, e.g., lithium thionyl chloride batteries. In other embodiments, e.g., where the batteries are used in conjunction with ultracapacitors capable of providing pulsed high peak power output, the batteries may be relatively low rated batteries (e.g., with relatively low power, voltage, and/or current ratings). In some such embodiments, the batteries may be substantially free of lithium. The batteries may be arranged in a serial or parallel fashion in the MP telemetry devices and systems disclosed herein. The batteries may be arranged in parallel to increase the current available to the MP telemetry devices and systems, but they may also be arranged in series to increase the voltage available to the MP telemetry devices and systems.

[135] In certain embodiments, the MP telemetry devices and systems disclosed herein may include any suitable power electronics including, e.g., power converters serving various power management roles, e.g., as described in PCT Publication No. WO/2014/145259 published September 18, 2014 . For example, the MP telemetry devices and systems disclosed herein may comprise an ultracapacitor charging circuit (UCC), crossover (XO) circuit, state of charge (SoC) circuit, ultracapacitor management (UMS) circuit, electronics management circuit, and any other suitable components.

Ultracapacitor Charger Circuit (UCC) [136] As noted above, the power systems for the MP telemetry devices and systems disclosed herein include a power converter. In further embodiments, the power converter may include UCC circuit for charging an energy storage device that includes one or more ultracapacitors. The UCC circuit features high temperature operation, e.g., greater than 75 degrees Celsius, e.g., greater than 125 degrees Celsius, e.g., 150 degrees Celsius or more, adjustable charge current control, redundant over voltage protection for the capacitor bank, and a wide input/output voltage range. In certain embodiments, the UCC may include a controller integrated circuit (controller IC) that uses current mode regulation to mitigate the effect of the art-known right half plane (RHP) zero on output voltage during load transients. In this respect, the UCC circuit of the present disclosure may provide an optimal range of operation whereby the converter is charging at a calibrated duty cycle to minimize overall losses, e.g., wherein the bus voltage is optimized.

[137] In certain embodiments, the UCC circuit uses switch mode power conversion, wherein at low ultracapacitor charge, the controller IC uses the more efficient, i.e., less lossy, current mode control, and subsequently switches to voltage control mode at greater levels of ultracapacitor charge storage where such switching would result in more efficient charging of the ultracapacitor.

[138] In certain embodiments, the power supply for MP telemetry devices and systems disclosed herein afford input current shaping, e.g., in applications where continuous and steady current draw from the energy source is desirable or a particular pulsed profile is best. In particular embodiments, such current shaping prevents undesirable electrochemical effects in batteries such as cathode freezeover effects or passivation effects.

[139] In certain embodiments, the power supply for the MP telemetry devices and systems disclosed herein affords input current smoothing, e.g., in applications where continuous and steady current draw from the energy source is desirable. In particular embodiments, such current smoothing reduces conduction losses in series resistances.

[14Θ] In certain embodiments, e.g., where the UCC circuit is operating in constant voltage mode, the UCC is capable of supplying a constant voltage in the event of a capacitor string disconnection. For example, the UCC can continue to source power into the load at a lower level.

[141] In one embodiment, the UCC controller is implemented digitally. The advantages of such a system include component reduction and programmability. In certain embodiments, the control of the switch network is performed by a microcontroller/microprocessor.

[142] In one embodiment, adjustable current may be established digitally with a Pulse Width Modulated (PWM) control signal created by a supervisor and a low pass filter to produce an analog voltage that a controller IC interprets as the controller IC does not communicate digitally. The controller IC is configured to regulate output current, e.g., the ultracapacitor charge current. Through control of the charge current, the UCC circuit is capable of regulating the voltage on the ultracapacitors, e.g., by hysteretic control wherein the voltage is kept within a voltage band by on-off control of the IC.

[143] The UCC circuit, in certain embodiments, may be digitally controlled. In further embodiments, the UCC circuit is digitally controlled by the electronics management system (EMS), e.g., as detailed below. In further embodiments, the UCC circuit can enter sleep mode to conserve energy and this aspect may be provided for by a digital control.

[144] The UCC controller can also be implemented in an analog fashion. In such a configuration, the feedback control would generally be carried out with the use of components such as operational amplifiers, resistors, and capacitors.

[145] In certain embodiments, the controller integrated circuit (IC) (e.g., a main controller IC at the center of the UCC) is electrically connected by modular bus stackers to and programmed to communicate with other circuits such as a junction circuit, an EMS circuit, a cross over circuit, and/or one or more energy sources (such as battery, generator, or wireline). The UCC circuit may also include a resistor network for voltage sampling, a step down power section (e.g., a Buck converter), a step up power section (e.g., a boost converter), an inductor current sense resistor required for current mode control, and/or a charge current sense resistor required for regulating the charge current.

[146] In certain embodiments, a power converter for charging an ultracapacitor is controlled hysteretically. For example, a charging current is regulated by the converter and a feedback control circuit. A voltage of an ultracapacitor is measured by the power converter or a supervisor or the like. The power converter may be disabled for instance when a voltage on an ultracapacitor reaches a certain threshold. Alternatively, the charging current may be reduced when the voltage reaches a certain threshold. In this way, various benefits may be realized. First, a voltage set point and hysteresis band may be set in firmware or software, i.e. digitally, without a redesign of feedback control circuitry, e.g. redesign that may otherwise be required for stability and dynamics. Thus, the output voltage is easily adjusted by a user or by a controller, e.g. in run-time. Second, whereas an efficiency of charging an ultracapacitor will generally be improved by limiting or regulating a charging current, and many loads expect a voltage within a range to operate properly, a controller having a feedback control for regulating a charging current may be used to provide for a voltage chosen to fall within a range to operate a load properly.

[Ϊ47] In certain embodiments, the UCC circuit regulates the power provided to the ultracapacitor during charging. In some embodiments, power regulation may be preferable to current regulation, e.g., in cases where it is desirable to increase or maximize charging speed.

Power regulation may be achieved with a current-regulated power converter architecture by way of an outer feedback loop (whereas the inner feedback loop is that which regulates the current of the converter). The outer feedback loop may regulate the power. For instance, the system may measure its own output voltage and multiply the measured value by the commanded current. The result is a power and the power actually delivered can be subsequently adjusted up or down by adjusting the commanded current up or down. The process may repeat indefinitely so that the actual power delivered to the formation tracks a commanded power set point.

[148] A similar situation exists in the case of voltage regulated power converter. The current output from the system may be measured and multiplied by the commanded voltage. The power may then be adjusted by adjusting the voltage command. The power control loop may be "slow" meaning it is slower than the inner current or voltage control loops.

Cross Over (XO) Circuit

[149] Various embodiments of the power supply for MP telemetry devices of the type described herein include a Cross Over (XO) circuit. In certain embodiments, the cross over circuit is a peripheral circuit board that can seamlessly be added into a modular architecture, e.g., through stackers electrically connected and controlled by a junction circuit board to enable the use of multiple power sources. In some embodiments, along with the UCC circuit, the cross over circuit possesses autonomous capability.

[ISO] In one embodiment, the cross over circuit can be preprogrammed to switch from one power source to another after the initial source has been depleted.

[151] In another embodiment, the cross over circuit has the ability to parallel two sources together and to either increase the power capable of being delivered to the load, or to extract the very last remaining energy of the individual power sources where the individual, nearly depleted sources could not deliver enough power to drive the load alone.

[152] The cross over circuit, in certain embodiments, may be digitally controlled by an electronics management system (EMS) (discussed in greater detail below) and can enter sleep mode to conserve energy.

[153] The cross over circuit may include a supervisor, and in certain embodiments is electrically connected (e.g, using modular bus stackers) to, and programmed to communicate with various circuits including: the junction circuit, the EMS circuit, state-of-charge circuit, and/or one or more energy sources (such as battery, generator, or ultracapacitor string) through the supervisor of the circuit. The cross over circuit may also include a current sense resistor; a resistor network for voltage sampling; a current sense resistor for state-of-charge measurements; a unidirectional primary disconnect that allows the BUS voltage to be bootstrapped to the primary source, where power is initially processed through a low forward voltage diode in parallel with the p-channel MOSFET to reduce dissipation during the bootstrapping operation and once voltage is established on the bus, the primary disconnect may be turned on (the p- channel MOSFET is enhanced) by a resistor-diode network and n-channel MOSFET; a bidirectional secondary disconnect that processes power from the secondary source to the BUS, where the secondary disconnect, unlike the primary disconnect, can fully disconnect the secondary source from the BUS; a resistor-diode network for biasing the gate of the p- channel MOSFET, sized to allow for low voltage disconnect operation (resistor divider) and high voltage disconnect operation (diode clamps the gate voltage to a safe operating voltage); and/or a bleed resistor to ensure the n-channel MOSFET is turned off in the absence of a control signal.

State of Charge (SoC) Circuit

[154] Various embodiments of the power supply for MP telemetry devices of the type described herein include a state of charge (SoC) circuit. In certain embodiments, the SoC circuit serves to provide for an estimate of the remaining and / or used capacity of a given energy source (e.g., an ultracapacitor or battery). This circuit can combine measured current, temperature, the time domain shape of the current profile, and can produce a model to determine the remaining runtime for a given energy source.

[155] Measurement of current is an important factor in determining the service time of an energy source, in particular, a battery. As such, in certain embodiments, current may be measured using an off-the-shelf IC that serves as a transconductance amplifier. In certain embodiments, current may be measured using Hall Effect sensors/magnetometers, inductive sensors, magnetic sensors, or high-side or low side current sense resistors

[156] Temperature may be measured using a resistance temperature detector (RTD), a resistor with a large temperature coefficient, (temperature dependent resistance). The resistance is read through the use of a resistor divider tied to the output pin of a microcontroller. The resistor divider is pulled up to 5V when a measurement is to be taken. Turning the resistor divider on and off saves power and reduces self-heating in the resistance. Other methods of measuring temperature include use of bi-metallic junctions, i.e. thermocouples, or other devices having a known temperature coefficient transistor based circuits, or infrared detection devices.

[157] These measurements can be used as inputs to a given model describing the behavior of a given energy source over time. For instance, great variations in battery current have been shown to reduce the rated capacity of a Li-SOCL2 battery. For this battery chemistry, knowledge of the current profile would be useful in determining the remaining capacity of the battery.

[158] The state of charge circuit may comprise a supervisor, and in certain embodiments is electrically connected by the modular bus stackers to, and programmed to communicate with: the junction circuit, the EMS circuit, the cross over circuit, and/or one or more energy sources (such as battery or ultracapacitor string) through the supervisor of the circuit. The state of charge circuit may also comprise an external comm bus implemented with pull up resistors; a voltage regulator used to establish an appropriate voltage for the supervisor and other digital electronics; a current sense circuit; unidirectional load disconnect, wherein a p-channel MOSFET is enhanced via a control signal to the pulldown n- channel MOSFET and a resistor divider ratio is chosen to allow proper biasing of the p- channel MOSFET at low voltage levels, while the Zener diode serves to clamp the maximum source-gate voltage across the MOSFET; and/or resistor divider networks and ADC buffer cap necessary for analog voltage reading

Uitracapacitor Management System (UMS) Circuit

[159] In certain embodiments, the power supply for MP telemetry devices and systems disclosed herein includes an uitracapacitor management system (UMS) circuit. The uitracapacitor management system circuit has the primary purpose of maintaining individual cell health throughout operation. The UMS circuit may measure individual cell voltages or voltages of a subset of cells within a string and their charge/discharge rates. The UMS circuit supervisor uses these parameters in order to determine cell health that may be communicated to the electronics management system (EMS) circuit to be included in optimization algorithms and data logs.

[16fi] Additionally, in certain embodiments, the UMS circuit is responsible for cell balancing and bypassing. Cell balancing prevents ultracapacitors from becoming overcharged and damaged during operation. Cell bypassing diverts charge and discharge current around an individual cell. Cell bypassing is therefore used to preserve efficient operation in the event that a cell is severely damaged or exhibiting unusually high equivalent series resistance (ESR).

[161] The UMS circuit is capable of determining individual cell health through frequent cell voltage measurements and communication of the charge current with the EMS. The cell health information may be relayed to the EMS circuit over the modular communication bus, e.g., through the modular bus stackers. The cell health information can then be used by the EMS circuit to alter system behavior. For example, consider that the EMS circuit is supporting high output power to a load by regulating to a high output capacitor voltage. If however, the UMS circuit reports that one or multiple ultracapacitors are damaged, the EMS can choose to regulate to a lower output capacitor voltage. The lower output voltage reduces output power capabilities but helps preserve uitracapacitor health. As such, in one embodiment, the UMS circuit offers a convenient method to independently control cell voltage levels while monitoring individual and uitracapacitor string cell health.

[162] In certain embodiments, the supervisor of the UMS circuit may communicate to the UMS core via an internal circuit communication bus. In this example, data and command signals are transferred over the internal communication bus. The supervisor controls the UMS core to measure each cell voltage. Depending on the state of charge, the supervisor commands the UMS core to balance each cell. In particular embodiments, the balance time and frequency is controlled via the supervisor to optimize cell health and to minimize heat increases that may arise during balancing. Cell health may be monitored by the supervisor and communicated by the supervisor to the EMS circuit via the modular bus. Additionally, in certain embodiments, through the use of external devices, e.g. MOSFETs, the supervisor can decide to bypass a given cell.

[163] The UMS Core has circuitry that enables measuring the voltage of individual cells. Additionally, the UMS core is capable of removing charge from individual cells to reduce the cell voltage. In one embodiment, the UMS core balances individual cells by dissipating the excess energy through a passive component, such as a resistance. In another embodiment, charge can be removed from one cell with high voltage and transferred to another cell with low voltage. The transfer of charge can be accomplished through the use of external capacitors or inductors to store and release excess charge.

[164 J In certain embodiments, since cell balancing and monitoring does not have to occur continuously, i.e., at all times, the UMS circuit may enter a low power sleep state. For instance, an EMS circuit may control the UMS circuit via the modular communication bus so that: (1) when not in use, the UMS circuit can go to a low power consumption mode of operation and (2) when called upon, the EMS circuit can initiate cell monitoring and balancing via the UMS supervisor.

[165] In certain embodiments, the modular bus enables bi-directional communication between the UMS circuit supervisor, EMS circuit, and other supervisor nodes on the communication bus. Power to the UMS circuit supervisor may also be provided through the modular bus.

[166] In certain applications, balancing circuitry may automatically balance a cell when the cell voltage exceeds a set voltage. This behavior affords the capability to perform real-time adjustments to the ultracapacitor string voltage. An UMS circuit may be configured to communicate on the modular bus thereby enabling real-time updates to cell balancing behavior. In addition, communication on the modular bus enables data to be stored external to the UMS circuitry. This modularity enables the UMS circuit to have a wide range of applications.

[167] In certain embodiments, the supervisor and modular bus allow for changes in the ultracapacitors and system requirements, such as logging resolution and lifetime, without requiring extensive revisions to UMS circuitry.

[168] In certain embodiments, the cell health information can be stored locally on the UMS circuit or stored by the EMS after transmission over the modular bus. The cell information can be useful in determining whether a bank of ultracapacitors needs to be replaced after usage or whether service is required on individual cells.

[169] In certain embodiments, when a cell experiences a high voltage, the UMS circuit is capable of discharging that cell to a lower voltage. By discharging the cell to a lower voltage, cell lifetime is improved. Maintaining balanced cell voltage over the entire string improves optimizes lifetime of the capacitor string.

[170] In certain cases, discharging a cell produces excess heat that can damage surrounding electronics. Furthermore, it is often advantageous to control the discharge current from a cell in order to prevent damage to the cell or excess thermal losses. As such, in certain embodiments, the UMS circuit is capable of controlling the discharge current profile, by distributing discharge currents across a widely separated circuit area, enabling improved thermal management and cell health. For example, heat caused by a discharging event is often localized to a section of the UMS circuit. If multiple cells need to be balanced, it is advantageous in order to reduce temperature increases not to balance cells that would cause temperature increases in adjacent location on the UMS circuit. Therefore, the UMS circuit manages temperature increases by selecting which cells to balance based on their spatial location on the UMS circuit. These features may be managed by a supervisor and additionally may be managed by an EMS and / or a combination of the above.

[171] In certain embodiments, the UMS circuit also manages temperature increases during balances by controlling the time of discharge. For example, instead of constantly discharging an ultracapacitor until the desired cell voltage is met, the supervisor chooses to start and stop charging periodically. By increasing the duty cycle between discharge events, temperature increases caused by cell discharge current can be mitigated.

[172] In certain embodiments, a damaged cell may exhibit a decreased capacitance compared to surrounding cells. In this case, the cell will exhibit higher charge and discharge rates. Normal balancing operations will mitigate any damage to the cell in this case. Similarly, in certain embodiments, a cell may exhibit increased leakage current, causing a constantly dropping cell voltage. A decreased voltage on a cell will require other cells to maintain a higher average voltage. Again, normal balancing operations will mitigate damage to cells in this case.

[1 3] In certain embodiments, a cell may be damaged to the point where it exhibits very high ESR, degrading the power handling of the entire capacitor string. In these cases, typical balancing operations will not fix the problem. At this juncture, the UMS circuit can choose to bypass any given cell. Cell bypassing may be achieved via nonlinear devices such as external diodes that bypass charge and discharge current, such that every other cell must store a higher average voltage. However, power handling capability of string is maintained. In certain embodiments, where there are multiple batteries and/or ultracapacitors connected in series or parallel series, it is important to both monitor and balance the state of charge of individual cells. The UMS circuit comprises of necessary circuitry to monitor and balance a string of ultracapacitors while including additional functionality to improve efficiency, system health, and thermal management.

[174] The UMS circuit in certain embodiments comprises a supervisor, is electrically connected by the modular bus stackers to, and programmed to communicate with: the junction circuit, the EMS circuit, the state of charge circuit, the cross over circuit, or other circuits in the MP telemetry devices and systems disclosed herein, and/or one or more energy sources (such as a battery, wireline or generator). The UMS circuit may also comprise an integrated circuit (IC) or controller for performing the functions of the UMS, switch devices such as transistors or diodes, and various ancillary components. The IC may be selected from off-the-shelf monolithic control IC's.

Electronics Management System (EMS) Circuit 175] In certain embodiments, the power supply for MP telemetry devices and systems disclosed herein includes an EMS circuit. The EMS circuit is a multifunctional device capable of one or more of the following: collecting and logging data of system performance and environment conditions; managing other circuits; and communicating to external systems for programming and data transmission.

[176] In certain embodiments, the EMS circuit hardware is tightly integrated with surrounding hardware, enabling the control and monitoring of total system behavior. The hardware may be complemented by intelligent firmware that manages the operation of several other microcontrollers, using external sensors and communication between the microprocessors to intelligently optimize system performance. The effect is an extremely versatile and capable system, one that can adapt in real-time to changes in the environment and requirements.

[177] In certain embodiments, the EMS circuit collects and logs data of system performance and environmental conditions. The EMS circuit, e.g., via the EMS circuit supervisor, is responsible for recording sensor data directly from external sensors and through communication over the modular bus from other circuits. This data may be used to evaluate system

performance for optimization. In general, significant events may also be logged for later evaluation.

[178] In certain embodiments, the EMS circuit manages surrounding circuits for optimal system performance. For example, the EMS circuit may control the UCC circuit charging current. The charging current may be selected based on the data collected throughout the system through sensors and communication with the circuits. The EMS circuit can also put various circuit components into a low power sleep state to conserve power when possible.

[179] In certain embodiments, the EMS circuit communicates to external systems for programming and / or data transmission. The external communication bus on the EMS circuit enables communication to outside hardware and software. This connection enables the EMS circuit to be reprogrammed while disposed in the system. The EMS can then reprogram other supervisors or direct other supervisors on their operation, effectively reprogramming the entire system. The external communication bus is also used to transmit data logs from internal memory to external software. In this way, data can be collected during operation and analyzed post-operation by external equipment, e.g., an external PC. [Ϊ8β] In one embodiment, the Electronics Management System (EMS) circuit serves to collect information from available supervisors and sensors and dependently control system behavior. The EMS also provides an interface to external electronics, such as PC software or firmware programmers. Through the external communication bus, it is possible to program the EMS circuit core, e.g., the EMS circuit supervisor, and consequently all other supervisors connected to the EMS circuit.

[181] The EMS circuit core may be comprised of one or more digital circuits, e.g., microcontrollers, microprocessor, or field-programmable gate array (FPGA) units. In certain embodiments, the EMS circuit core is connected to a load connect/disconnect circuit that allows the ultracapacitor string to be connected or disconnected to an external load. The capacitor string may be disconnected from the load if, for example, the capacitor string voltage is too low or too high for the particular load. During normal run-time operation, the load is connected to the ultracapacitors through a load driver circuit.

[182] In certain embodiments, the EMS circuit is connected to additional sensors that are not interfaced to other supervisors. These sensors may include one or more of the group consisting of a temperature sensor, a load current sensor, an input battery current sensor, an input voltage sensor, and a capacitor string voltage sensor.

[183] Through the modular bus, the EMS circuit may be connected to other circuits. The communication bus may comprise data line, a clock line, and an enable line. In some embodiments, supervisors interface to the data, clock, and enable lines. Furthermore, each supervisor can be prescribed an identification address.

[184] In one embodiment, to communicate over the internal communication bus, the EMS circuit activates the enable line and sends over the data and clock lines the identification address of the target supervisor followed by the desired data command instructions. When the supervisors see the enable line activated, each supervisor will listen for its prescribed identification address. If a supervisor reads its identification address, it will continue to listen to the EMS circuit message and respond accordingly.

[1 5] In this way, communication is achieved between the EMS circuit supervisor and all other supervisors. In certain embodiments, the EMS circuit interfaces with the UCC circuit and controls the UCC circuit charge current. The charge current is controlled to regulate the output ultracapacitor voltage.

[186] Feedback control and/or heuristic techniques are used to ensure safe and efficient operation of the electronics, ultracapacitors, and input battery stack. In certain embodiments, the EMS circuit interfaces with the cross over circuit to record and potentially control the battery connection state. The state of the cross over circuit and crossover events may be logged via the EMS and internal/external memory. In certain embodiments, the EMS circuit interfaces with the UMS circuit in order to monitor and log cell health and/or discharge events.

[187] In certain embodiments, the EMS circuit is capable of bringing supervisors into a low power state to decrease power consumption and optimize run-time behavior. As described herein, the EMS circuit has a unique hardware structure that allows communication to and from a large variety of sensors, lending itself to a variety of advantages that generally serve to optimize one or more performance parameters, e.g., efficiency, power output, battery lifetime, or capacitor lifetime.

[188] The EMS circuit in certain embodiments comprises a supervisor, is electrically connected by the modular bus stackers, and programmed to communicate with: the junction circuit, the UMS circuit, the state of charge circuit, the cross over circuit, and/or one or more energy sources (such as battery or ultracapacitor string) through the supervisor of the circuit.

[189] The EMS circuit may also comprise at least one digital controller, e.g. a

microcontroller, a microprocessor , or an FPGA, and various ancillary components.

Load Driver Circuit

[190] In certain embodiments, the MP telemetry devices and systems disclosed herein may comprise a load driver circuit, e.g., to drive the MP pulser,.

[1 1] The load driver circuit, in certain embodiments, acts as a power converter that may provide an aspect of regulation, for instance voltage regulation of the output of to the MP telemetry device or system despite another widely varying voltage aspect. For example, when a power source is intermittent, e.g. it provides power for several minutes and then ceases to provide power for several minutes, an power supply disclosed herein may be required to provide power to a load, e.g., a mud pulser, when the power source is not providing power. In this example, an HTRESD may provide the stored energy for the supply of power during the period when the power source is not providing power. If the HTRESD is a capacitor, for instance an ultracapacitor, a limited energy capacity of said HTRESD may lead to a widely varying voltage of said HTRESD during a period when the MP telemetry devices or systems are transmitting data but the power source is not providing power. A load driver circuit may be employed in this example to provide for a regulated load voltage despite the widely varying HTRESD voltage. The load driver circuit may function as a power converter so that it processes the power drawn from said HTRESD and delivered to said load and so that it also incorporates said regulation aspects, i.e., a regulated power converter, in this example, an output voltage regulated power converter. Generally, a regulation aspect is enabled by feedback regulation techniques, e.g., of the type described herein.

[192] In certain embodiments, a controller integrated circuit (IC) at the center of the load driver circuit, is electrically connected (e.g., by modular bus stackers) to and programmed to communicate with the remainder of the MP telemetry devices and systems disclosed herein. For example, in certain embodiments, the remainder of the MP telemetry devices and systems disclosed herein may comprise various circuits. Non- limiting examples include a junction circuit, at least one sensor circuit, an ultracapacitor charger circuit, an ultracapacitor management system circuit, a changeover circuit, a state of charge circuit, and an electronic management system circuit.

[193] In certain embodiments, the MP telemetry devices and systems disclosed herein further comprises modular circuit boards. In further embodiments the modular circuit boards are circular. In further embodiments, the modular circuit boards are stacked. In further

embodiments, the modular circuit boards are circular and stacked.

[1 4] In certain embodiments, the power source comprises at least one of a wireline power source, a battery, or a generator.

[Ϊ 95] In certain embodiments, the power source comprises at least one battery. In this embodiment, the MP telemetry devices and systems disclosed herein may further comprise a cross over circuit, particularly when the power source comprises more than battery. In particular embodiments, the MP telemetry devices and systems disclosed herein further comprises a state of charge circuit board.

[196] In certain embodiments, the power source comprises a wireline, and at least one battery, e.g., a backup battery. In those embodiments, the MP telemetry devices and systems disclosed herein may further comprise a cross over circuit. In particular embodiments, the MP telemetry devices and systems disclosed herein further comprises a state of charge circuit.

[1 7] In certain embodiments, the power source comprises a generator.

[198] In certain embodiments, the power source comprises a generator, and at least one battery, e.g., a backup battery. In this embodiment, the MP telemetry devices and systems disclosed herein may further comprise a cross over circuit. In particular embodiments, the MP telemetry devices and systems disclosed herein further comprises a state of charge circuit.

[199] In certain embodiments, the circuit boards may be combined to provide multifunctional circuit boards.

[2ββ] The load driver circuit features high temperature operation, e.g., greater than 75 degrees Celsius e.g., greater than 125 degrees Celsius, e.g., 150 degrees Celsius or more, and may comprise any of an adjustable charge current control, redundant over voltage protection for the capacitor bank, and a wide input/output voltage range, and voltage mode regulation.

[201] In certain embodiments, the load driver charges a capacitor, e.g. an ultracapacitor. In these embodiments, an adjustable current may be established digitally with a Pulse Width Modulated (PWM) control signal created by a supervisor and a low pass filter to produce an analog voltage that the controller IC interprets as the controller IC does not communicate digitally. The controller IC is configured to regulate output current, e.g., the ultracapacitor charge current. Through control of the charge current, the UCC circuit is capable of regulating the voltage on the ultracapacitors, e.g. by hysteretic control wherein the voltage is kept within a voltage band by on-off control of the IC.

[202] The load driver circuit, in certain embodiments, may be digitally controlled. In further embodiments, the load driver circuit is digitally controlled by the electronics management system (EMS). In further embodiments, the load driver circuit can enter sleep mode to conserve energy and this aspect may be provided for by a digital control.

[203] The load driver controller can also be implemented in an analog fashion. In such a configuration, the feedback control would generally be carried out with the use of components such as operational amplifiers, resistors, and capacitors. While effective, a minor disadvantage of this configuration is the inherent lack of flexibility controlling charge current and output voltage.

[204] In certain embodiments, the controller integrated circuit (IC) at the center of the load driver circuit is electrically connected by modular bus stackers to and programmed to communicate with the junction circuit, the EMS circuit, cross over circuit, and/or one or more energy sources (such as battery, generator, or wireline). The load driver circuit may also comprise a resistor network for voltage sampling, a step down power section (e.g., a Buck converter), a step up power section (e.g., a boost converter), an inductor current sense resistor required for current mode control, and/or a charge current sense resistor required for regulating the charge current.

[285] In one embodiment, the load driver circuit controller is implemented digitally. The advantages of such a system include component reduction and programmability. In certain embodiments, the control of the switch network is performed by a

microcontroller/microprocessor.

Amplifier Circuit

[206] As described in detail above, various embodiments of the power supply for the MP telemetry devices described herein include one or more circuits for processing high power levels. The following described devices and techniques that may be used in various embodiments for efficient power processing.

[207] Processing of high power levels often requires very efficient power electronics.

Inefficiencies in power electronics result in temperature increases that can damage electronics and ultracapacitors. Therefore, in order to process significant power, high efficiency power electronics are often required. The class D topology, is art-recognized, as designed for high efficiency operation. High efficiency is achieved by running the output transistors in either a fully enhanced or off state. When fully enhanced, the MOSFETs can ideally be considered a short with no internal resistance. In this state, there is high current but no voltage drop over the output transistors, resulting in no power loss. In their off state, the MOSFETs ideally block all current at high voltage, resulting in no power loss. In present embodiment, the MOSFETs are not considered ideal switches, but rather power losses are mitigated through properly chosen switching frequencies and low loss components. The above essentially describes the basic concepts associated with art-recognized switch-mode operation. When switched-mode operation is applied to amplifiers, those amplifiers are often termed class-D amplifiers.

Switched mode power supplies of the present MP telemetry devices and systems have a high operating efficiency, e.g., at least 50%, at least 70%, or at least 90%.

[2Θ8] In certain embodiments, a class D Amplifier enables significantly higher power capabilities when compared to existing solutions. In a particular embodiment, the amplifier comprises six main components connected in a Class D full bridge switching amplifier configuration, i.e., also together referred to as a Class D amplifier: (1) High voltage capacitor rail; (2) Modulator; (3) device drivers; (4) Switching Section; (5) Signal low pass filters; and (6) Load impedance.

High_.Voltage Capacitor _.Rail

[209] The high voltage capacitor rail supplies a positive rail voltage to the output transistors. In order to deliver significant power to the load, it is important that the high voltage capacitor rail maintain low impedance, minimizing power losses under heavy loads.

Modulator

[218] The modulator has the function of modulating the signal provided to the load, e.g., to encode telemetry data onto the signal. The modulator may function in a number of ways. The modulator may modulate a number of quantities, e.g. power, voltage, current, frequency, phase, pulse width, pulse position, pulse amplitude, and combinations thereof.

[211] An example open-loop method for modulating amplitude of the voltage presented to the load includes providing a time-varying analog signal as a time-varying reference input to a pulse-width modulator circuit, e.g., a comparator having two inputs, one being said reference, the other being a triangle wave signal oscillating at the desired switching stage switching frequency, the pulse-width modulator circuit providing the pulse width modulated gate driver control signal. By time-varying the reference voltage input to the pulse width modulator circuit, the duty ratio of the gate driver control signal is also varied, the duty cycle of said control signal in turn may control the instantaneous voltage presented to the load.

[212] An example closed-loop method for modulating amplitude of the voltage presented to the load includes providing a time-varying analog signal as a time-varying reference input to a feedback control circuit, the feedback control circuit configured to regulate the voltage presented to the load by various methods known in the art. Generally, the feedback circuit comprises measurement aspects of feedback signals, an error amplifier, a dynamic

compensator, a pulse width modulator, a gate driver, which may comprise a dead- time circuit. The dynamic compensator is generally designed to achieve a combination of closed-loop stability and closed-loop dynamics.

[213] In various embodiments, the modulator may be configured to implement any suitable encoding or data transmission schemes known in the art. Applicants have realized that statistics based encoding schemes are particularly suitable for use in noise environments found in typical drilling operations. For example, in various embodiments, various pieces of data intended to be transmitted are associated with random or pseudorandom sequences of numbers. To transmit a given piece of data, a signal modulated with the associated random signal as transmitted from the downhole transmitter. A topside receiver receives the transmission, combined with possible noise. The receiver uses statistical techniques (e.g., a least squares technique) to determine which of the random or pseudorandom sequences is most likely to correspond to the received signal. This "most likely" sequence is then used to determine the transmitted data. Such techniques are particularly suited for detecting the transmitted signal in the presence of non- random noise, e.g., mains noise, noise associated with drilling motors, generators, or other electrical components common in drilling operations.

[214] A variety of such statistics based techniques known from the field of

telecommunication may be used, e.g., linear prediction techniques such as code-excited linear prediction, vector sum excited linear prediction, algebraic code excited linear prediction, time division multiple access (e.g., of the type used in cellular communication standards such as GSM), code division multiple access, frequency division multiple access, orthogonal frequency division multiple assess, spread spectrum, frequency hoping spectrum, and the like.

Device Drivers

[215] The device drivers generally provide current or voltage amplification, voltage level shifting, device protection and in some cases signal dead time generation in order to properly drive the transistor inputs. Generally device drivers convert a low level control signal to a signal appropriate for controlling a device. Example devices include bipolar junction transistors, MOSFETs, JFETs, Super junction transistors or MOSFETs, silicon- controlled rectifiers, insulated gate bipolar transistors and the like. Gate drivers may be provided as discrete implementations or as off-the-shelf or monolithic integrated circuits.

Switching Section

[216] The switching section comprising generally comprises output transistors switches processes input power to provide a transformed power to the load. An example switching section is configured in a full bridge configuration such that the two of the transistors are on at any gi ven time. In one state, two transistors are on, providing a current flo through the load in one direction. In the other state, the other two transistors are on, providing a current flow through the load in the opposite direction. Filtering

[217] Each of the transistors are switched at a frequency well above the bandwidth of the reference signal. In order to accurately recreate an amplified version of the reference signal over the load, low pass filters are used to filter out the high frequency switching signal, ideally leaving only the low frequency reference signal transmitted through the load. The low pass filters are reactive components to prevent losses that would other occur over resistance components. Filtering between the switching section and the load should pass the frequency content desired in the modulated signal to the load. Meanwhile, the filtering may be band- limited enough to reject unwanted frequency content.

Load

[218] In present invention, the load impedance represents, e.g., the electric drive motor used to operate an MP telemetry device. Load impedances may contain high order behav ior models, however, are represented by a power resistor,

[21 ] While switching amplifiers may introduce switching artifacts in the output signal, in certain embodiments, these artifacts are minimized through the use of properly selected switching frequencies, and/or well-designed filtering. In a particular embodiment, the output filter preserves signal integrity by severely attenuating switching artifacts while preserving the information contained in the reference signal. The output filter may also contribute minimal power loss through having very lo resistance components

[228] The components of the MP telemetry devices and systems described herein may be electrically connected by a variety of known means. For example, some or all of the components may be connected through a power bus incorporated in the downhole toolstring (a "toolstring power bus" or "TPB"). A TPB may provide power and/or data in a single channel or across multiple channels. Alternatively or additionally, some or all of the components of the MP telemetry devices and systems described herein may be connected by an internal bus system, which is separate from the TPB that extends across the entire toolstring. The internal bus system may be used to transmit data and'Or power signals within the MP telemetry devices and systems described herein. In addition, certain connections may be a simple wired connection between a positive and a negative output terminal. An illustrative embodiment is shown by reference to FIG. 1 8.

[221] As shown in FIG. 18, certain embodiments of the power supply 3 for MP telemetry devices and systems disclosed herein may include a power management circuit (e.g., including an EMS circuit, UCC, and/or otiier power management components as described above), which may be, e.g., a switched mode power supply with a high operational efficiency, for efficiently drawing power from a downhole power source, which may be a battery pack, a generator, or a topside power source (e.g., a generator connected to the toolsiring by a wireline). The power management circuit efficiently manages power consumption fro the power source and the charging of an HTRESD configured to meet the power need of the high power MP telemetry device (e.g., an ultracapacitor bank, such as an ultracapacitor string comprising 1-100 ultracapacitors and related electronics),

[222] In various embodiments, the HTRESD may be characterized by a volumetric storage power density of greater than 30 kW/L, 40 kW/L, 50 kW/L, 75 kW/^'L, 100 kW/L. 110 kw/L, 120 kW/L, or more, e.g., in the range of 30 kW/L to 120 kW/L or any sub-range thereof.

Accordingly, the HTRESD may facilitate high power transmission, while maintaining a form factor suitable for the tight confines often found in downhole applications. For example, in some embodiments, HTRESD may be generally cylindrical and elongated, with an outer diameter (OD) of less than 36 inches, 12 inches, 6 inches, 3 inches, 2 inches, 1 inch, 0,5 inches, or less, e.g., in the range of 0.5 inches to 36 inches or any sub-range thereof, such as 0.5 inches to 3 inches.

[223] MP telemetry device circuitry may receive both power and data through the internal telemetry system bus. In those embodiments, the MP telemetry circuit may draw power from the HTRESD for both high power pulses and general circuit operation. Alternatively or additionally, the MP telemetry circuit may receive power from both an internal telemetry system bus and a power source, which may be provided through the TPB. In those

embodiments, the MP telemetry circuit may draw a low current from downhole power source for general circuit operation and a high power pulses from the HTRESD during high power MP transmission windows. The MP telemetry circuit in conjunction with the power management circuit controls the overall power consumption to maximize the operational efficiency of the MP telemetry devices, systems, and methods disclosed herein.

[224] In the present invention, the HTRESD allows for a mode of operation in which the HTRESD is charged from a low power source (e.g., from a relatively low voltage and/or low- current supply such as a battery or downhole generator) and then discharged at a relatively higher power. The system provides for bursts of high power telemetry. The bursts of high power telemetry are provided at a power level higher than that which is available from the low power source. To operate in this mode, the transmission must comprise periods of non- transmission or at least periods when the transmission is provided at lower power levels than the power levels during bursts of high power telemetry. To maintain an energy balance, the relative on-time of the transmission compared to the off-time fundamentally dictates the ratio between the power level of the high power bursts and the maximum power available from the source. For instance, if the transmission on-time is one ninth that of the transmission off- time, the system can provide for bursts of telemetry with up to ten times the power available from the low power source.

[225] In certain other embodiments, MP telemetry devices and systems disclosed herein may be further connected to other devices within the downhole toolstring— e.g., other downhole instruments or other power sources, such as one or more primary batteries, downhole generators, or topside power sources— through a TPB or through other electrical connections. A TPB may he used to both provide send electrical power to and from the MP telemetry devices and systems disclosed herein and to allow the devices or systems to commimicate with other devices within the toolstring. For example, the MP telemetry devices and systems disclosed herein may communicate with an MP telemetry tool connected to the TPB to receive information from the MP telemetry tool and transmit that information using the MP telemetry tool. Such "dual telemetry" systems are described in US Patent os. 6,909,667, 7,573,397, 8,120,509, and 8,502,696, which are incorporated herein by reference in their entirety.

[226] In certain embodiments, the MP telemetry devices and systems disclosed herein are capable of communicating with other downhole tools and/ or devices on the surface. The device and systems may employ various communication modes and protocols to facilitate this communication. For example, communication within a toolstring between downhole tools may be facilitate by a TPB, which provides a wired electrical connection among devices connected to the toolstring. The TPB may be further connected electrically to the surface, e.g., where wired pipe is employed in the drilling operation. An example of wired pipe is the IntelliServ™ wired pipe available from National Oilwell Varco. Additionally or alternatively, the MP telemetry devices and systems disclosed may be capable of communicating with in the toolstring by any other available communication methods, including without limitation optical communication (e.g., fiber optic communication), electromagnetic communication (e.g., radio frequency communication), and/or mechanical communication (e.g., rotary or mud pulse communication). By enabling communication between the MP telemetry devices and systems disclosed herein and the other tools within the toolstring, the MP telemetry devices and systems disclosed herein can operate more efficiently.

[227] In certain embodiments, the MP telemetry devices and systems receive data directly from other downhole instruments (e.g., a directional sensor, a nuclear magnetic resonance tool, a coring tool, a sonic tool, a neutron density tool, a gamma detector tool, a seismic

measurement tool, a telemetry tool, a resistivity tool, and/or a formation tester), generate a power MP telemetry signal based on that data, and transmit the MP telemetry signal to a downhole detector or receiver. In some embodiments, one or more downhole instruments transmit data through, and the MP telemetry devices and systems receive data from, a TPB. In some embodiments, one or more downhole instruments transmit data through a direct connection to the MP telemetry devices and systems disclosed herein.

[228] Certain embodiments of the MP telemetry devices and sy stems disclosed herein are capable of communicating with other downhole instruments (e.g., a directional sensor (sometimes called a directional module), a resistivity sensor, a gamma sensor, or any other downhole instruments) through a TPB. The data processing unit, sometimes called a master processing unit or MP LT, facilitates She processing of data recei ved from She various downhole tools. The data processing unit generally does not require high power and may he powered by the downhole power source and/or the energy storage (e.g., HTRESD) incorporated in the MP telemetry device. The data processing unit generates an MP signal based on the data received from various downhole tools. For example, in certain embodiment of the MP telemetry devices, systems, and methods disclosed herein, the data processing unit may produce a signal used to create a pressure pulse sequence using a mud pulser based on digital data received from various downhole instruments.

[229] As described in detail herein, in some embodiments, the MP telemetry circuit may operate in a burst mode, transmitting only during certain time periods, e.g., to take advantage of high power pulses available from the HTRESD and allow for recharging of the HTRESD between pulses. However, in some embodiments, an incumbent sensor or other device may- send information to the MP telemetry device in a continuous signal stream. In some such embodiments, the MP telemetry circuit may modify the continuous signal to generate a modified output signal suitable for burst transmission. For example, the MP telemetry circuit may include one or more buffers that store data from the low power signal during periods where the high power MP telemetry circuit is non-transmitting.

[230] In some embodiments, blanks may be inserted in a data stream such that actual data is only included in the signal at times when high power MP telemetry circuit is transmitting. In some embodiments, the duration or frequency of the blanks periods in the data stream may be used to set the output power level of the MP transmission. For example, longer ore more frequent blank periods (allowing for longer or more frequent recharging periods) may indicate the use of a higher transmission power level.

[231] In certain embodiments, the MP telemetry devices and systems disclosed herein can adjust the charge of the HTRESDs or the output power, current, or voltage profile based on available input power and/or available information about MP telemetry tool operations.

Additionally or alternatively, the MP telemetry devices and systems disclosed herein can communicate with the MP telemetry tool to anticipate and schedule events related to the MP telemetry tool operation, e.g., power pulses required for an MP transmission period.

[232] When the MP telemetry devices and systems disclosed herein include HTRESDs, the devices and systems are also rechargeable, i.e., they are capable of supplying power to an MP telemetry tool through at least 2 charge- discharge cycles. Systems and devices incorporating HTRESDs may be recharged between discharge cycles (e.g., power pulses experienced during a high power MP transmission window) by a variety of power sources, including primary batteries (such as common lithium thionyl chloride batteries), turbines, flywheels, inertial energy generators, and other downhole power sources. Alternatively or additionally, the MP telemetry devices and systems disclosed herein may he powered by a topside power source (e.g., a wireline or a wired pipe) connected to the downhole toolstring through known means.

[233] When the MP telemetry devices, systems, and methods disclosed herein employ HTRESDs (e.g., one or more ultracapacitors), certain embodiment may comprise devices for regulating the charging and discharging of the HTRESDs systems. Where the MP telemetry devices and systems comprise multiple HTRESDs, the MP telemetry devices and systems may further comprise de vices for regulating the charging and discharging of indi vidual HTRESDs or groups of HTRESDs, e.g., balancing charge between HTRESDs or monitoring the charge state or other performance parameters of an HTRESD or group of HTRESDs.

[234] Having thus described aspects of novel MP telemetry devices, systems, and methods, it should be recognized that a variety of embodiments may be realized. For example, the devices, systems, and methods disclosed herein may include circuits that provide a state of charge monitor for monitoring charge in at least one of the HTRESDs, including ultracapacitors, or another power source (such as a battery) coupled to the MP telemetry devices and systems, e.g., a downhole power source connected to a TPB. In certain embodiments, the MP telemetry devices and systems disclosed herein may include control circuitry for drawing power from one or more of several battery packs arranged, for example in a redundant configuration. In certain embodiments, the devices, systems, and methods disclosed herein may further comprise a motor drive, e.g., a brushless motor drive. In certain embodiments, the devices, systems, and methods disclosed herein may include various sensors, such as pressure, temperature and vibration (which may provide output to control circuitry for controlling an MP telemetry device or system as appropriate), rotation, and the like.

[235] The power supplies disclosed herein may employ a variety of optimization and efficiency based approaches to delivering power to an MP telemetry tool. For example, the power supply may be capable of communicating with the MP telemetry tool to optimize the data transmission rate based on the available power, which may vary instantaneously. For example, MP telemetry devices and systems employing at least one HTRESD may be able to provide high power pulses during a first high data transmission rate mode when the HTRESD is in a high state of charge. When the HTRESD is in a relatively lower state of charge, or is in a recharging mode between discharge cycles, the MP telemetry devices and systems disclosed herein are capable of communicating with the MP telemetry, which can adjust to a second reduced data transmission mode. Power and data transmission rate can be adjusted across the full spectrum of available and transmission.

[236] The power supply for the MP telemetry devices and systems disclosed herein are capable of adjusting the state of an associated charge storage device, e.g., an HTRESD, particularly an ultracapacitor, based on the mode of operation of the MP telemetry tool and, generally, the drilling operation. For example, during a drilling mode the at least one HTRESD may be held at a first charge state wherein the HTRESD provides power to the MP telemetry tool sufficient for basic operation, e.g., data collection, whereas the at least one HTRESD may be held at a second charge state (e.g., a higher charge state) during a transmission mode wherein the HTRESD provides high power pulses to the transmitting MP telemetry tool.

[237] In certain em odiments, the MP telemetry devices and systems disclosed herein enable prioritization of data transmission based on a variety of downhole conditions, including available power and type of data being transmitted. For example, the MP telemetry devices and systems disclosed herein enable transmission of relatively low bandwidth data (e.g., directional drilling data, such as azimuth and inclination) in a first low power (e.g., low bit rate) transmission mode. The MP telemetry devices and systems disclosed herein can then transmit high bandwidth data during a second higher power (e.g., higher bit rate) transmission mode, e.g., after acquisition of gamma data, neutron density data, seismic data, or a nuclear magnetic resonance data.

[238] In some embodiments, the power supply for the MP telemetry devices and systems disclosed herein may regulate output power, e.g., to trade off signal integrity for battery life. For example, in some embodiments, the transmission power may be reduced when a low battery state of charge is detected (e.g., as described in greater detail herein). Power regulation may also be used to limit power dissipation, e.g., in high power scenarios.

[239] In some embodiments, power rather than current regulation of the system is a useful feature because it directly controls the amount of power drawn from the downhole power source. Power regulation may be achieved with a current-regulated power converter architecture by way of an outer feedback loop (whereas the inner feedback loop is that which regulates the current of the converter). The outer feedback loop may regulate the power. For instance, the system may measure its own output voltage and multiply the measured value by the commanded current. The result is a power and the power actually delivered can be subsequently adjusted up or down by adjusting the commanded current up or down. The process may repeat indefinitely so that the actual power delivered to the formation tracks a commanded power set point.

[240] A similar situation exists in the case of voltage regulated power converter. The current output from the system may be measured and multiplied by the commanded voltage. The power may then be adjusted by adjusting the voltage command. The power control loop may be "slow" meaning it is slower than the inner current or voltage control loops. The inner control loops generally need to be faster than the frequency content of the controlled signal, e.g., the frequency of the sinusoidal output of the transmitter, while the pow er control loop only needs to be as fast as typical changes in the load. Generally, voltage, current or power set points in the context of the downhole MP telemetry devices, systems, and methods disclosed herein may- represent amplitude, peak to peak, peak or Root Mean Square (RMS) power setpoints or actual set points that vary in time continuously according to the signal to be output to the load (e.g. the MP pulser). [241] In certain embodiments of the MP telemetry devices and systems disclosed herein, parallel power converters are employed. Parallel power converters enable numerous advantageous features of the MP telemetry devices and systems described herein, MP telemetry devices and systems employing parallel power converters more efficiently deliver high current to an MP pulser. In addition, parallel power converters provide redundancy that extends the operability of the MP telemetry devices and systems after a failure of one of the parallel power converters. Thus, the MP telemetry de vices and systems disclosed herein employing parallel power converters are capable of operating for longer uninterrupted periods in a downhole environment and are less likely to require an expensive and time consuming breaking of the toolstrmg to retrieve and replace a failed MP telemetry device or system.

[242] In certain embodiments, an ultracapacitor charging circuit is capable of charging at least one ultracapacitor or a bank of ultracapacitors while a separate circuit is capable of balancing the charge across the ultracapacitor bank.

[243] In certain embodiments, the MP telemetry devices and systems disclosed herein comprise an amplifier to amplify the signal output from the MP telemetry tool.

[244] In certain embodiments, the amplifier comprises a differential output its output: comprises two terminals, neither of which is also connected to the system's internal ground reference.

[245] In certain embodiments, the amplifier comprises a single-ended output - its output comprises two terminals, one of which is also connected to the system's internal ground reference.

[246] In certain embodiments, the amplifier comprises a switched-mode amplifier (e.g., a class-D amplifier).

[247] In certain embodiments, the amplifier comprises a linear amplifier.

[248] In certain embodiments, the amplifier comprises a half-bridge or a push-pull circuit for generating a single-ended output signal.

[249] In certain embodiments, the amplifier comprises two push-pull circuits or an H-bridge circuit for generating a differential output signal.

[250] In certain embodiments, the amplifier is controlled so that a differential output signal is bi-polar - the difference between the two output terminals takes on both positive and negative values. In those cases, the amplifier output may be controlled to be substantially zero-mean.

[251] In certain embodiments, the amplifier comprises an output circuit that is controlled to continuously modulate the current or voltage output from the power supply to the MP pulser. In certain embodiments, continuous modulation is achieved by way of pulse-width modulation by operating the transistors comprising the output circuit as switches. In these cases, the output circuit is said to be switched at a frequency much higher than the fundamental of the out ut signal frequency . In certain embodiments, continuous modulation is achie v ed by way of linear operation using the transistors comprising the output circuit. In these cases, the output circuit is said to operate as a linear amplifier,

[252] In certain embodiments, the amplifier comprises a switch network such as an H-bridge that is controlled to switch between various DC levels in order to construct a piece-wise linear approximation of the desired output signal. In these cases, the switch network is said to be switched at the fundamental of the output signal frequency.

[253] In certain embodiments, the amplifier comprises a switch network such as an H-bridge that controls the polarity of a continuously varying input voltage or current. For instance if a sinusoidal output signal is desired, the switch network may switch the polarity of a rectified sinusoidal output signal at each of the desired zero-crossings to construct an un- rectified sinusoid. In these cases, the switch network is said to be switched at the fundamental of the output signal frequency.

[254] In certain embodiments, the amplifier comprises a switch network such as an H-bridge and additionally comprises a current-regulated power converter. The current- regulated power converter may be controlled to generate a rectified version of the desired signal and the switch network such as an H-bridge may be controlled to invert the polarity of the output of the current-regulated power converter in order to create an un-rectified output current signal. In other embodiments the amplifier comprises a voltage-regulated power converter instead of the current-regulated power converter.

[255] In certain embodiments, the amplifier is augmented with a second relatively slow control loop for regulating the power output from the amplifier.

[256] Additionally or alternatively, the MP telemetry devices and systems disclosed herein may comprise a slow power loop feedback to control the power provided to the MP telemetry tool. When combined with a current regulating power converter, a slow feedback loop measuring output voltage of the MP telemetry devices and systems provide a measurement of the output power, which provides a feedback mechanism for adjusting current to a desired setpoint, i.e., the current demand of the MP telemetry tool. The power control loop may enable indirect measurement of the aggregate resistance through which the MP telemetry tool is transmitting (i.e., the resistance of the formation plus the drilling fluid).

[257] In general, the MP telemetry devices, systems, and methods disclosed herein are adapted for operation in the harsh environment encountered downhole. For example, the MP telemetry devices and system, and HTRESDs, when included, are adapted, in some embodiments, for operation in a temperature range from ambient temperatures up to about 250 °C, or even higher temperatures in certain embodiments.

[258] Some exemplary off-the-shelf components and techniques that may be used in the MP telemetry devices and systems disclosed herein include: (1 ) bare die silicon and silicon-on- insulator active devices, (2) silicon carbide active power devices, (3) high temperature rated and low temperature coefficient ceramic passives (COG or NPO dielectrics), and (4) high temperature magnetic passives. AN (aluminum nitride) ceramics may be used as a circuit substrate materia! for excellent thermal stability and thermal conductivity. Circuit interconnects may be formed of oxidation resistant Au traces. Bonding strategies may employ flip chip or Au or Al wire bonding for bare die active components using, for instance, AuGe high temperature solder. In some embodiments, wire bonding is expected to be advantageous over flip chip bonding due to the added mechanical compliance, especially in the presence of thermal expansion and shock and vibration. Also, many conventional devices - e.g. devices comprising conventional silicon wafers - are rated for relatively high temperatures and/or may be independently qualified as reliable for operation at relatively high temperatures. For instance, silicon integrated circuits formally rated by their manufacturer for operation at temperatures only up to about 85 degrees Celsius may be tested and verified independently to operate reliably at temperatures up to, for instance 150 degrees Celsius, 175 degrees Celsius, 200 degrees Celsius, or even up to 300 degrees Celsius or more . This process of qualification beyond the manufacturer's specification is generally time-consuming and may be costly, but can yield useful high temperature circuit building blocks.

[259] High temperature circuit techniques may be employed, for example, to ensure stability of feedback regulation circuits despite very wide temperature swings as passive circuit components used for frequency compensation may van,' in value. Low or essentially zero temperature coefficient circuit designs can be achieved by coupling negative temperature coefficient resistors with conventional resistors, by closely matching active devices and by relying on ratiometric (relative) rather than absolute sensing and control. As an example, bandgap derived voltage references can be employed to cancel the effect of very wide temperature variations on set points in feedback regulation circuits. Temperature coefficient strategic component selections mitigate these problems as well, for instance CGO or NPO dielectric ceramic capacitors have a relatively fiat response to temperature across this range. Active device performance variations can be significantly mitigated by use of silicon - on- insulator (SOT) and silicon carbide (SiC) technology widely available in both hermetic and bare die form.

[260] Other high temperature materials, components and architectures as are known in the art may be employed to provide for operability at a specified (high) temperature. Silicon-on- insulator (SOI), Silicon Carbide (SiC), bare die components, ceramic PCB's, low temperature coefficient passives and high temperature, hi-rel solders will all be sourced to complete the electronic systems. Such components are described in US Patent Publication os. U82012/068074 and US2013/G026978, which are incorporated herein by reference in their entirety.

[261] In certain embodiments, the MP telemetry devices and systems disclosed herein are capable of communicating with devices on the surface through a variety of "downlink" communication modes, including without limitation wired electrical communication (e.g., wired pipe such as mte!iiServ), optical communication (e.g., fiberoptic communication), electromagnetic communication (e.g., radio frequency communication or quasi-static time varying current or voltage based communication), mechanical communication (e.g., rotary or mud pulse communication), and/or ultrasound communication.

[262] A mechanical downlink may be a rotary downlink in which information is

communicated by varying the rotational rate of the drillstring. A downhole rotational rate sensor detects the variations in rotational rate which can be interpreted by the MP telemetry device or system. The downhole rotational rate sensor may be iniegrated into the MP telemetry devices and systems disclosed herein or may be part of an external sensor array capable of communicating such rotational rate information to the MP telemetry devices and systems, e.g., by sending the rotational rate information through a toolstring power bus. In this manner, information can be transmitted from the surface to the downhole MP telemetry devices and systems.

[263 J In various embodiments, one or more components of the downhole MP telemetry device or system may operate in a transmit mode for uplinking data from downhole to topside (as described in detail above) and a receive mode for downlinking data from topside to downhole,

[264] The MP telemetry devices and systems described herein can be arranged in a variety of configurations within a toolstring. In certain embodiments, the MP telemetry devices and systems described herein can be arranged to satisfy different form factors for toolstrings, including probe- and collar-mounted toolstrings.

[265J In some embodiments, the power supply for the high power MP telemetry devices described herein may include a mechanically strong housing (e.g., an aluminum housing) configured to protect internal electronic components. In some embodiments the housing may^¬ be configured to contain at least two double sided rectangular circuit boards, e.g., extending along the cylindrical axis of the housing and stacked in a direction transverse to the axis.

[266] In some embodiments, the housing may act as a heat sink for the electronics housed within. For example, the most dissipative circuit elements (e.g., resistors and inductors) may be mounted closest to the housing.

[267] In some embodiments the circuit boards may be mounted in a floating configuration, with no hard connections to the housing. Each of the circuit board may rest on an electrically insulating pad, and may be potted in place. In some embodiments, the potting material may be configured to withstand thermal expansion and contraction, e.g., by inclusion voids in the material. Spacers may be positioned between the circuit boards. The spacers may be at least partially floating to allow for thermal expansion and contraction.

[268] In some embodiments, the housing may include one or more wire chase features. The wire chase features may include smooth, contoured surfaces configured to reduce or eliminate wear on the wires.

[269] In some embodiments, the housing may be connected to an adjacent element using bolts or other fasteners. The bolts may be disposed about the outer periphery of the cylindrical housing. The housing may include one or more electrical connections with adjacent element. An interlock feature may be provided to transfer strain away from the connecting bolts and electrical connections. For example the interlock feature may be disposed at an end of the housing near its central axis.

[270] Although the examples provided above focus on providing telemetry for a downhole tool, such as a drill, it is to be understood that the devices and techniques provided herein may be used for ay suitable application, including other types of subsurface communication or telemetry.

[271] Incorporation By Reference

[272] The entire contents of ail patents, published patent applications and other references cited herein, including, but not limited those listed in Table 2 below, are hereby expressly incorporated herein in their entireties by reference. To the extent that anything included in the incorporated material conflicts with the present application, the present application shall control.

Table 2

Tool

[273] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents were considered to be within the scope of this invention and are covered by the following claims. Moreover, any numerical or alphabetical ranges provided herein are intended to include both the upper and lower value of those ranges. In addition, any listing or grouping is intended, at least in one embodiment, to represent a shorthand or convenient manner of listing independent embodiments; as such, each member of the list should be considered a separate embodiment.

[274] It should be recognized that the teachings herein are merely illustrative and are not limiting of the invention. While the invention has been described with reference to exemplary embodiments, it will be understood that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated to adapt a particular instrument, siixiation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed but to be construed by the claims appended herein.

Claims

What is claimed is,

1. An apparatus comprising:

a power supply; and

a rotary mud pulse telemetry device comprising:

a drive motor configured to be powered by the power supply; and a rotating actuator configured to be driven by the drive motor to modulate the flow of fluid through a borehole to encode information from a down hole location;

wherein the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 100 inch pounds for at least a pulse period of time.

2. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 200 inch pounds for at least the pulse period of time.

3. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 300 inch pounds for at least the pulse period of time.

4. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 400 inch pounds for at least the pulse period of time.

5. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 500 inch pounds for at least the pulse period of time.

6. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 750 inch pounds for at least the pulse period of time.

7. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 1 ,000 inch pounds for at least the pulse period of time.

8. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 1,500 inch pounds for at least the pulse period of time.

9. The apparatus of any preceding claim, the power supply and drive motor are configured to cooperate to drive the rotating actuator with a torque of at least 2,000 inch pounds for at least the pulse period of time.

10. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 50 W.

11. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 100 W.

12. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 250 W.

13. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 500 W.

14. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 1,000 W.

15. The apparatus of any preceding claim, wherein the power supply is configured to power the drive motor with a peak delivered power of at least 1,500 W.

16. The apparatus of any preceding claim, wherein the power supply comprises a high temperature rechargeable energy storage configured to operate at temperatures throughout an operating temperature range, wherein the operating temperature range comprises 0 degrees Celsius to 125 degrees Celsius.

17. The apparatus of claim 16, wherein the operating temperature range comprises 0 degrees Celsius to 150 degrees Celsius.

18. The apparatus of any one of claims 16 and 17, wherein the operating temperature range comprises 0 degrees Celsius to 210 degrees Celsius.

19. The apparatus of any one of claims 16 to 18, wherein the operating temperature range comprises 0 degrees Celsius to 250 degrees Celsius.

20. The apparatus of any one of claims 16 to 19, wherein the operating temperature range comprises -40 degrees Celsius to 125 degrees Celsius.

21. The apparatus of claims 16 to 20, wherein the operating temperature range comprises -40 degrees Celsius to 150 degrees Celsius.

22. The apparatus of any one of claims 16 to 21, wherein the operating temperature range comprises -40 degrees Celsius to 210 degrees Celsius.

23 The apparatus of any one of claims 16 to 22, wherein the operating temperature range comprises -40 degrees Celsius to 250 degrees Celsius.

24. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of vibrations of at least 10 G^ at frequencies in the range of 50 Hz to 500 Hz.

25. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of vibrations of at least 20 G^ at frequencies in the range of 50 Hz to 500 Hz..

26. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of vibrations of up to 30 G^ at frequencies in the range of 50 Hz to 500 Hz..

27. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of vibrations of up to 50 G^ at frequencies in the range of 50 Hz to 500 Hz..

28 The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of shock of up to 500 G with a duration of at least 0.05 milliseconds.

29. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of shock of up to 1,000 G with a duration of at least 0.05 milliseconds.

30. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of shock of up to 1,500 G with a duration of at least 0.05 milliseconds.

31. The apparatus of any preceding claim, wherein the power supply is configured to operate in the presence of shock of up to 2,000 G with a duration of at least 0.05 milliseconds.

32. The apparatus of any preceding claim, wherein the power supply comprises:

a rechargeable energy storage coupled to a first energy source;

wherein:

the rechargeable energy storage is configured to be charged by the first energy source; and

the rechargeable energy storage is configured to provide one or more pulses of output power having a peak power greater than a maximum peak power output of the first energy storage.

33. The apparatus of claim 32, wherein the rechargeable energy storage comprises at least one ultracapacitor and the first energy source comprises at least one of: a battery, a wire line source, a downhole generator, and combinations thereof.

34. The apparatus of claim 32 or 33, wherein the rotary mud pulse telemetry device is configured to transmit a signal comprising at least one silence period, and wherein the first energy source is configured to at least partially charge the rechargeable energy storage during the at least one silence period.

35. The apparatus of any preceding claim, wherein the rotary mud pulse telemetry device is noncompensated.

36. The apparatus of claim 35, wherein:

the drive motor is positioned within an internal housing, the housing being filled by a gas at about atmospheric pressure; and

the rotary mud pulse telemetry device further comprises:

a drive shaft extending from the drive motor to a position external of the internal housing, the drive shaft connected to the rotating actuator; and

a seal positioned about the drive shaft and configured to seal the internal housing while allowing rotary motion of the drive shaft.

37. The apparatus of claim 36, wherein the seal comprises:

a plurality of seal elements; and

a plurality of seal carriers holding said plurality of seal elements;

wherein:

the plurality of seal elements includes a group of outer seal elements and a group of inner seal elements,

each outer seal element of the group of outer seal elements is maintained by the seal carrier in a position juxtaposed against a surface of a pulser body disposed radially about the seal;

each inner seal element of the group of inner seal elements is maintained by the seal carrier in a position juxtaposed against a radial surface of the drive shaft; and

the seal elements of the plurality of seal elements are each held by a respective one of the plurality of seal carriers such that the group of outer seal elements and the group of inner seal elements are arranged in an alternating pattern.

38. The apparatus of claim 37, wherein:

the group of outer seal elements comprises at least five seal elements, and the group of inner seal elements comprises at least four seal elements.

39. The apparatus of claim 37 or 38, wherein the seal comprises a seal cartridge defining a longitudinally extending bore configured to receive the drive shaft, the seal cartridge comprising:

a front end cartridge segment configured to be positioned distal the internal housing and comprising a seal carrier for at least one of the outer seal elements;

a back end cartridge segment configured to be positioned proximal the internal housing and comprising a seal carrier for at least one of the outer seal elements;

a plurality of intermediate cartridge segments disposed in series between the front end cartridge segment and the back end cartridge segment, wherein each intermediate cartridge segments comprises a seal carrier for at least one of the outer seal elements; and

wherein the respective seal carrier for each inner seal element of the group of inner seal elements is formed by a connection of an intermediate segment with one of: another intermediate segment, the front end cartridge segment, and the back cartridge segment.

40. The apparatus of any one of claims 37 to 39 wherein the group of inner seal elements comprises:

at least one polymeric wiper seal positioned distal to the internal housing and at least one spring loaded seal positioned more proximal the internal housing than the polymeric wiper seal.

41. The apparatus of any one of claims 37 to 40, wherein the group of outer seal elements comprises one or more t-shaped seal elements.

42. The apparatus of any one of claims 37 to 41, wherein at least one of the inner or outer seal elements comprises a polypak or poly-0 type seal element.

43. The apparatus of any preceding claim, wherein the apparatus is configured to be mounted up hole of a bottom hole assembly.

44. The apparatus of claim 43, wherein the apparatus is configured to be wire line retrievable.

45. The apparatus of claim 44, wherein:

the apparatus comprises at least one centralization feature configured to centralize the apparatus within the borehole; and

the apparatus comprises a separator device configured to separate the at least one centralization feature from the apparatus to facilitate wire line retrieval.

46. The apparatus of claim 45, wherein: the at least one centralization feature comprises a fin, and

the separator device comprises a fin cutter configured to be actuated during wireline retrieval to cut the fin.

47. The apparatus of claim 45 or 46, comprising a stinger adapted for removable connection to a muleshoe mount of a downhole toolstring element,

wherein at least one calibrated shear element is used to secure the stinger to the muleshue; and

wherein the calibrated shear element is configured to remain intact during normal operation of the apparatus, but to shear off in response to an applied force above a threshold level during wireline retrieval.

48. The apparatus of any preceding claim, wherein the rotating actuator comprises:

a rotor; and

a stator;

wherein each of the rotor and stator are formed of a wear resistant carbide material.

49. The apparatus of claim 48, wherein the rotating actuator comprises:

a drive shaft extending between the drive motor and a rotor; and

at least one bi-directional thrust bearing at least partially supporting the drive shaft.

50. The apparatus of any preceding claim, comprising a removable wear element disposed at a location corresponding to a weight bearing connection between the apparatus and a drill string.

51. The apparatus of claim 50, wherein the removable wear element comprises a wear cuff.

52. The apparatus of claim 50 or 51, comprising a removable erosion element disposed at a location exposed to fluid flow during operation of the apparatus.

53. The apparatus of any preceding claim, wherein the apparatus has an elongated probe shaped form factor with a radial outer diameter of less than about 4 inches

54. The apparatus of any preceding claim, wherein the apparatus has an elongated probe shaped form factor with a radial outer diameter of less than about 3 inches

55. The apparatus of any preceding claim, wherein the apparatus has an elongated probe shaped form factor with a radial outer diameter of less than about 2.5 inches

56. The apparatus of any preceding claim, wherein the rotary mud pulse telemetry device defines a primary flow path for drilling fluid and a bypass flow path for drilling fluid.

57. The apparatus of claim 56, further comprising a diverter mechanism for diverting drilling fluid to the bypass flow path based on a flow rate of the drilling fluid.

58. The apparatus of claim 57, wherein the diverter mechanism is configured to divert drilling fluid to the bypass flow path in response to the flow rate reaching or exceeding a threshold rate.

59. The apparatus of claim 58, wherein the threshold rate is at least about 600 gallons per minute.

60. The apparatus of any one of claims 57 to 60 wherein the diverter mechanism comprises at least one selected from the list consisting of: a flow control valve, Venturi tube device, a vaned passage, and combinations thereof.

61. The apparatus of any preceding claim, wherein the pulse period is in the range of 0.5 seconds to 3 seconds.

62. The apparatus of any preceding claim, wherein the pulse period is in the range of 0.5 seconds to 5 seconds.

63. The apparatus of any preceding claim, wherein the pulse period is in the range of 0.5 seconds to 10 seconds.

64. The apparatus of any one of claims 1 to 60 preceding claim, wherein the pulse period is in the range of 0.1 seconds to 10 seconds.

65. A mud pulse telemetry kit comprising:

a power supply module

rotary mud pulse telemetry device module; and

a linear mud pulse telemetry device module;

wherein the power supply module is configured to be selectively attachable to each of the rotary mud pulse telemetry device module and the linear mud pulse telemetry device module.

66. The kit of claim 66, wherein, when attached, the power supply module and the rotary mud pulse telemetry device module comprise the apparatus of any one of claims

67. The kit of any one of claims 65 to 66, wherein the power supply module is configured output a peak power of at least 50 W.

68. The kit of any one of claims 65 to 66, wherein the power supply module is configured output a peak power of at least 100 W.

69. The kit of any one of claims 65 to 66, wherein the power supply module is configured output a peak power of at least 250 W.

70. The kit of any one of claims 65 to 66, wherein the power supply module is configured is configured output a peak power of at least 500 W.

71. The kit of any one of claims 65 to 66, wherein the power supply module is configured output a peak power of at least 1,000 W.

72. The kit of any one of claims 65 to 66, wherein the power supply module is configured output a peak power of at least 1,500 W.

73. The kit of any one of claims 65 to 72, wherein the power supply module comprises a high temperature rechargeable energy storage configured to operate at temperatures throughout an operating temperature range, wherein the operating temperature range comprises 0 degrees Celsius to 125 degrees Celsius.

74. The kit of claim 73, wherein the operating temperature range comprises 0 degrees Celsius to 150 degrees Celsius.

75. The kit of claim 73, wherein the operating temperature range comprises 0 degrees Celsius to 210 degrees Celsius.

76. The kit of claim 73, wherein the operating temperature range comprises 0 degrees Celsius to 250 degrees Celsius.

77. The kit of claim 73, wherein the operating temperature range comprises -40 degrees Celsius to 125 degrees Celsius.

78. The kit of claim 73, wherein the operating temperature range comprises -40 degrees Celsius to 150 degrees Celsius.

79. The kit of claim 73, wherein the operating temperature range comprises -40 degrees Celsius to 210 degrees Celsius.

80. The kit of claim 73, wherein the operating temperature range comprises -40 degrees Celsius to 250 degrees Celsius.

81. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of vibrations of at least 10 G^.

82. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of vibrations of at least 20 G_ms.

83. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of vibrations of up to 30 G_m^.

84. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of vibrations of up to 50 G_m^.

85. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of shock of up to 500 G with a duration of at least 0.05 milliseconds.

86. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of shock of up to 1,000 G with a duration of at least 0.05 milliseconds.

87. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of shock of up to 1,500 G with a duration of at least 0.05 milliseconds.

88. The kit of any one of claims 65 to 80, wherein the power supply module is configured to operate in the presence of shock of up to 2,000 G with a duration of at least 0.05 milliseconds.

89. The kit of any one of claims 65 to 88, wherein the power supply module comprises:

a rechargeable energy storage coupled to a first energy source;

wherein:

90. The kit of claim 89, wherein the rechargeable energy storage comprises an ultracapacitor and the first energy source comprises at least one of: a battery, a wire line source, a downhole generator, and combinations thereof.

91. The kit of claim 89 or 90, wherein at least one of the a rotary mud pulse telemetry device module and the linear mud pulse telemetry device module is configured to cooperate with the power supply module to transmit a signal comprising at least one silence period, and wherein the first energy source is configured to charge the rechargeable energy storage during the at least one silence period.

92. The kit of any preceding claim, wherein rotary mud pulse telemetry device module and the power supply module are configured to, when attached, form the apparatus of any one of claims 1 to 64.

93. A method for transmitting information from a drill string positioned at a down hole location in a bore hole to a surface location, the drill string having a flow passage through which a drilling fluid flows, the method comprising the steps of:

providing a telemetry apparatus approximate the down hole location, the telemetry apparatus comprising:

a power supply; and

a rotary mud pulse telemetry device comprising:

a drive motor configured to be powered by the power supply; and a rotating actuator configured to be driven by the drive motor; and modulating a flow of the drilling fluid to encode the information to be transmitted to the surface location;

wherein modulating the flow of the drilling fluid comprises causing power supply and drive motor to cooperate to drive the rotating actuator with a peak torque level of at least 100 inch pounds for at least a pulse period of time.

94. The method of claim 93, wherein modulating the flow of the drilling fluid comprises:

measuring drilling fluid pressure to detect a predetermined drop of drilling fluid pressure and then a subsequent predetermined rise of drilling fluid pressure; and

generating a sequence of positive pressure pulses in the drilling fluid at a position approximate the down hole location that propagates in a direction towards the surface location, the sequence of positive pressure pulses being generated at a time after the predetermined rise of drilling fluid pressure is detected, the sequence of positive pressure pulses are encode with the information to be transmitted to the surface location.

95. The method of claim 94, further comprising the step of:

directing the drilling fluid across a rotor of the rotary mud pulse telemetry device positioned approximate the down hole location,

wherein causing power supply and drive motor to cooperate to drive the rotating actuator comprises causing the rotor to successively (a) at least partially obstruct the flow passage by rotating into a first position and (b) partially reducing the obstruction by rotating into a second position.

96. The method of claim 95, wherein causing power supply and drive motor to cooperate to drive the rotating actuator comprises

locating the drive motor within a gas filled housing defined by a body of the rotary mud pulse telemetry device, and driving the rotating actuator using a drive shaft extending from the drive motor at least partially outward of the internal housing and terminating at a connection with the rotor, the drive shaft extending axially through the seal received by the body such that the seal seals the internal housing.

97. The method of any one of claims 94 to 96, further comprising the step of:

measuring a down hole parameter at a time after the predetermined drop of drilling fluid pressure is detected.

98. The method of claim 97, wherein the down hole parameter is selected from a group consisting of: inclination of the drill string, azimuth of the drill string, temperature, shock, vibration, pressure, and voltage.

98. The method of any one of claims 93 to 98 further comprising:

adding loss circulation material (LCM) to the drilling fluid;

wherein modulating a flow of the drilling fluid comprises modulating the flow of drilling fluid containing the LCM.

99. The method of claim 98, wherein the LCM has a median particle size of at least 500 μηι.

100. The method of claim 98, wherein the LCM has a median particle size of at least 750 μηι.

101. The method of claim 98, wherein the LCM has a median particle size of at least 1,000 μηι.

102. The method of claim 98, wherein the LCM has a median particle size of at least 1,500 μηι.

103. The method of claim 98, wherein the LCM has a median particle size of at least 2,000 μηι.

104. The method of any one of claims 98 to 103, comprising adding the LCM to the drilling fluid at a rate of at least 2 pounds per fluid barrel (p/bbl).

105. The method of any one of claims 98 to 103, comprising adding the LCM to the drilling fluid at a rate of at least 5 p/bbl.

106. The method of any one of claims 98 to 103, comprising adding the LCM to the drilling fluid at a rate of at least 10 p/bbl.

107. The method of any one of claims 98 to 103, comprising adding the LCM to the drilling fluid at a rate of at least 20 p/bbl.

108. The method of any one of claims 98 to 103, comprising adding the LCM to the drilling fluid at a rate of at least 30 p/bbl.

109. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least

1.2.

110. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least 1.3.

11 1. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least 1.4.

112. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least 1.5

113. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least 2.0.

114. The method any one of claims 98 to 108, wherein the LCM has a specific gravity of at least 2.5

115. The method of any one of claims 93- 1 14, comprising:

delivering a pulse of power from the power supply to the drive motor drive the rotating actuator with the peak torque level to clear an obstruction from the rotating actuator.

116. The method of claim 1 15, comprising detecting the obstruction and delivering the pulse of power in response to the detection.

117. The method of claim 1 15 or claim 1 16, wherein the power supply comprises a rechargeable energy storage, and wherein delivering the pulse of power comprises at least partially discharging the energy storage.

118. The method of claim 1 17, wherein the rechargeable energy storage comprises at least one ultracapacitor.

119. The method of any one of claims 93 to 1 18, wherein:

the power supply comprises a rechargeable energy storage; and

modulating a flow of the drilling fluid to encode the information to be transmitted to the surface location comprises:

encoding the information using a signal that includes at least one period of transmission silence;

at least partially charging the rechargeable energy storage during at the least one period of transmission silence.

120. The method of any one of claims 93 to 1 18, wherein the peak torque level is at least 200 inch pounds.

121. The method of any one of claims 93 to 118, wherein the peak torque level is at least 300 inch pounds.

122. The method of any one of claims 93 to 118, wherein the peak torque level is at least 400 inch pounds.

123. The method of any one of claims 93 to 118, wherein the peak torque level is at least 500 inch pounds.

124. The method of any one of claims 93 to 1 18, wherein the peak torque level is at least 1 ,000 inch pounds.

125. The method of any one of claims 93 to 118, wherein the peak torque level is at least 2,000 inch pounds.