Adapter and shaped charge apparatus for optimized perforation jet

Abstract

An adapter for a shaped charge includes a plurality of members configured to be secured to an inner surface of a shaped charge case. Each member of the plurality of members is spaced apart from each other such that the adapter has a central open area. According to an aspect, a securing mechanism is configured to secure the member to an inner surface feature of the shaped charge case.

Description

BACKGROUND

Perforating gun assemblies are used in many oilfield and gas well completions. In particular, the assemblies may be used for, among other things, any or all of generating holes in downhole pipe/tubing (such as a steel casing) to gain access to an oil/gas deposit formation and to create flow paths for fluids used to clean and/or seal off a well and perforating the oil/gas deposit formation to liberate the oil/gas from the formation. The perforating gun assemblies are usually cylindrical and include a detonating cord arranged within the interior of the assembly and connected to shaped charges, hollow charges or perforators disposed therein. The detonating cord is used to initiate/detonate the shaped charges. Once the detonating cord is activated by, for example a detonator, a detonation wave travels through a length of the detonating cord to initiate each shaped charge. Once the detonation wave passes by the initiation point of each shaped charge, another detonation wave is created that sweeps through the shaped charge. A liner and/or other materials within the shaped charge are collapsed and propelled out of the shaped charge in a perforating jet of thermal energy and solid material. The shaped charges may be designed such that the physical force, heat, and/or pressure of the perforating jet, expelled materials, and shaped charge explosion will perforate, among other things, steel, concrete, and geological formations.

Shaped charges for perforating guns used in wellbore operations come in many shapes/geometries. For example, shaped charges typically include a case that is dimensioned to receive liners of various shapes (such as, hemispherical, conical, frustoconical, or rectangular). The shape of the shaped charge and the corresponding liner housed therein, determines the geometry of the perforating jet and/or perforation (hole) that is produced by the charge upon detonation. Hemispherical, conical, and frustoconical shaped charge liners (typically housed in conical shaped charges or rotational symmetric shaped charges) tend to produce round/(semi-) circular perforations, while rectangular, or “slotted”, shaped charges tend to produce rectangular and/or linear perforations (“slots”). Particular geometries may be useful for specific applications in wellbore operations. For example, conical charges may produce a concentrated perforating jet that penetrates deep into a geological formation, to enhance access to oil/gas formations. On the other hand, slotted shaped charges may be useful in forming overlapping rectangular slots to allow full 360-degree access through a wellbore casing to flow concrete and seal a wellbore upon abandonment.

Upon detonation of the shaped charge, a perforation jet forms a perforation hole in a target. The geometry of the perforation (hole) that is produced by the shaped charge depends, at least in part, on the shape of the shaped charge case. Shaped charges with round/circular cases tend to produce round/circular perforations. An example of a conical shaped charge 10 is illustrated in FIG. 1A and FIG. 1B. As illustrated in FIG. 1A, the shaped charge 10 includes a case 20 (i.e., a conical case), an explosive load 30 housed in the case and a liner 40 disposed over the explosive load 30. A cross-sectional view of the shaped charge 10 (shown in FIG. 1B) illustrates that the shaped charge has a circular cross-section, which produces round perforations 50 (FIG. 1C) in a target. Shaped charges with rectangular or “slotted” cases tend to produce rectangular and/or linear perforations. The linear perforations can overlap each other in a helical pattern, and thereby perforate a cylindrical target around all 360° of the target. Such a pattern may be useful during abandonment of a well, where concrete is pumped into the well and must reach and seal substantially all areas of the wellbore.

One disadvantage of existing shaped charges is that the geometry of the shaped charge and associated perforating jet is set when the shaped charge is manufactured according to corresponding specifications. As such, during manufacture of shaped charges, multiple shaped charge cases must be manufactured when conical and slotted shaped charges are both desired. The particularized use of different shaped charge cases thereby increases the costs and efforts associated with, e.g., manufacturing smaller batches of shaped charges, holding inventory of specific shaped charge cases.

Based at least on the above considerations, devices, systems, and methods for changing the types of perforation geometry of a shaped charge case can help to facilitate would provide economic and logistical benefits. For example, a standard conical shaped charge case may be adapted with a device during assembly of the shaped charge and its components to produce a variety of perforation geometries, thus saving on manufacturing costs for customizing shaped charges and obviating the need to keep a variety of shaped charge cases at a wellbore location.

BRIEF SUMMARY

Embodiments of the disclosure are associated with an adapter configured for use with a shaped charge. The adapter includes a plurality of members configured to be secured to an inner surface of a shaped charge case. A securing mechanism may also be provided to secure the member to an inner surface feature of the shaped charge case. According to an aspect, each member of the plurality of members is spaced apart from each other such that the adapter has a central open area.

Embodiments of the disclosure may be associated with an adapter for a shaped charge. The adapter includes a collar; and a plurality of members secured to the collar in a spaced apart configuration from each other such that the adapter has a central open area. According to an aspect, the collar and the plurality of members are secured to an inner surface of a shaped charge case.

Further embodiments of the disclosure are associated with a shaped charge. The shaped charge includes a shaped charge case having an inner surface and an outer surface. According to an aspect, the inner surface defines a hollow interior of the shaped charge case. An adapter is positioned in or otherwise coupled to the inner surface of the shaped charge case. According to an aspect, the adapter includes a plurality of members secured to the inner surface in a spaced apart configuration from each other, such that the adapter has a central open area. The shaped charge includes an explosive load that is disposed within the hollow interior atop the adapter, such that the explosive load covers the adapter and is in direct contact with a portion of the inner surface of the shaped charge case. According to an aspect, a liner is disposed adjacent the explosive load. At least a portion of the adapter displaces some of the explosive load such that the adapter is configured to produce an atypical geometry perforating jet upon detonation of the shaped charge.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A more particular description will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments thereof and are not therefore to be considered to be limiting of its scope, exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1A is a cross-sectional view of standard conical shaped charge, according to the prior art;

FIG. 1B is a cutaway view of the shaped charge of FIG. 1A, taken along lines 1B-1B;

FIG. 1C is a perforation hole geometry created upon detonation of the shaped charge of FIG. 1A;

FIG. 2A is a perspective view of an adapter including a plurality of members having a securing mechanism, according to an embodiment;

FIG. 2B is a top down, perspective view of a shaped charge configured for receiving and securing the adapter of FIG. 2A;

FIG. 2C is a cutaway view of a shaped charge including the adapter of FIG. 2A secured in a shaped charge case;

FIG. 3A is a perspective view of an adapter including a plurality of members having a securing mechanism, according to an embodiment;

FIG. 3B is a top down view of the adapter of FIG. 3A;

FIG. 3C is a bottom up view of the adapter of FIG. 3B;

FIG. 3D is a top down, perspective view of a shaped charge configured for receiving and securing the adapter of FIG. 3A;

FIG. 3E is a cutaway view of a shaped charge including the adapter of FIG. 3A, illustrating securing mechanisms of the adapter engaged in internal surface features, according to an embodiment;

FIG. 4A is a cross-sectional view of a shaped charge including the adapter of FIG. 2A, an explosive load and a conical liner;

FIG. 4B is a cross-sectional view of a shaped charge including the adapter of FIG. 3A, an explosive load and a conical liner;

FIG. 5 is a perspective view of an adapter for a shaped charge, illustrating the adapter having a collar connecting a plurality of members, in accordance with an embodiment;

FIG. 6A is a top, perspective view of a shaped charge having the adapter of FIG. 5 positioned therein, in accordance with an embodiment;

FIG. 6B is a top, perspective view of the shaped charge of FIG. 6A, illustrating an explosive load partially covering the adapter;

FIG. 6C is a top view of the shaped charge of FIG. 6B, illustrating the explosive load completely covering the adapter;

FIG. 7A is a cross-sectional view of a conical shaped charge having the adapter of FIG. 5 positioned therein, according to an embodiment;

FIG. 7B is a cutaway view of the shaped charge of FIG. 7A;

FIG. 8A illustrates a perforation hole geometry created upon detonation of a conical shaped charge including an adapter, in accordance with an embodiment;

FIG. 8B illustrates a perforation hole geometry created upon detonation of a conical shaped charge including an adapter, in accordance with an embodiment;

FIG. 9A is a perspective view of a conical shaped charge, according to an embodiment;

FIG. 9B is a perspective view of an adapter, an explosive load and a liner configured for being positioned in the shaped charge of FIG. 9A;

FIG. 9C is a perspective view of the adapter of FIG. 9B;

FIG. 10 is a side view of a conical shaped charge including the adapter of FIG. 9C, in accordance with an embodiment;

FIG. 11A is a cutaway view of the shaped charge of FIG. 10, in accordance with an embodiment;

FIG. 11B is a cross-section view of the shaped charge of FIG. 10, taken along lines B-B;

FIG. 11C is a cross-section view of the shaped charge of FIG. 10, taken along lines C-C;

FIG. 11D is a cross-section view of the shaped charge of FIG. 10, taken along lines D-D;

FIG. 12A is a cross-section view of a shaped charge including an adapter, illustrating the adapter having an elliptical cross-section, according to an embodiment;

FIG. 12B is a cross-section view of a shaped charge including an adapter, illustrating the adapter having a straight cross-section, according to an embodiment;

FIG. 12C is a cross-section view of a shaped charge including an adapter, illustrating the adapter having a block cross-section, according to an embodiment;

FIG. 13 is a cross-section view of a shaped charge including an adapter, according to an embodiment;

FIG. 14 is a cross-section view of a shaped charge including an adapter, according to an embodiment;

FIG. 15 is a perspective view of an adapter, according to an embodiment;

FIG. 16 is a perspective view of an adapter, illustrating keys formed thereon, according to an embodiment;

FIG. 17 is a perspective view of an adapter positioned in a shaped charge case, according to an embodiment;

FIG. 18 is a cross-section of a shaped charge case that is modified to receive and secure an adapter within a hollow interior of the shaped charge case, according to an embodiment;

FIG. 19 is a top-down view of the shaped charge case of FIG. 18;

FIG. 20 is a cross-section view of a shaped charge including an adapter and a detonating cord receptacle arranged about the initiation point of the shaped charge, according to an embodiment;

FIG. 21 is a perspective view of a shaped charge case with a modified detonating cord receptacle, according to an embodiment;

FIG. 22 illustrates a perforation hole formed with a shaped charge including an adapter, according to an embodiment;

FIG. 23 illustrates a perforation hole formed with a shaped charge including an adapter, according to an embodiment;

FIG. 24 illustrates a perforation hole formed with a shaped charge including an adapter, according to an embodiment; and

FIG. 25 illustrates a perforation hole formed with a shaped charge including an adapter, according to an embodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments.

For purposes of this disclosure, the phrases “apparatus”, “device(s)”, “system(s)”, and “method(s)” may be used either individually or in any combination referring without limitation to disclosed components, grouping, arrangements, steps, functions, or processes.

The exemplary embodiments relate generally to a shaped charge and an adapter/insert coupled to an inner surface of a shaped charge case to change a particular geometry of a perforating jet and/or perforation produced by the shaped charge. According to an aspect, the adapter is secured or otherwise coupled to the inner surface a conical shaped charge case so that detonation of the shaped charge causes a rectangularly-shaped perforation and/or linear slot and/or elliptical shaped perforation to be formed in a target, rather than a traditional round/circular perforation. The adapters described herein change the inner geometry of the shaped charge case to create different explosive forces across the liner, which results in slot shaped perforation holes.

For purposes of illustrating features of the embodiments, various embodiments are introduced and referenced throughout the disclosure. These embodiments are illustrative and not limiting, and examples are provided purely for explanatory purposes.

FIG. 1A is a cross-sectional view of standard conical shaped charge, according to the prior art. Such a standard conical shaped charge may include additional features as those described according to the present disclosure to create an alternate perforation hole geometry.

FIG. 1B is a cutaway view of the shaped charge of FIG. 1A, taken along lines 1B-1B.

FIG. 1C is a perforation hole geometry created upon detonation of the shaped charge of FIG. 1A. As illustrated, the perforation created by the conical shaped charge has a circular/round shape.

FIG. 2A and FIG. 3A illustrate an adapter/insert/internal inlay 100 configured for use with a shaped charge assembly/shaped charge 200. The adapter 100 includes a plurality of members 104 configured to be secured to an inner surface 204 of a shaped charge case 201. The members 104 are formed from an inert material that does not react with other materials/components of a shaped charge. According to an aspect, the entire adapter 100 is formed from an inert material. The adapter 100 may be 3D printed, injection molded or machined. The adapter 100 may be formed from a polymer. The adapter 100 may have a density range of about 1.05 g/cm3 to about 2.5 g/cm3. According to an aspect, the members 104 include a rigid or semi-rigid material that includes at least one of a plastic material or rubber material, a polymer, a metal, and the like. According to an aspect, the members 104 comprise wood. The members 104 may be composed of any compressible material that can be adopted to the shape of the members 104. For example, the members 104 may include a salt-based material, with or without a binder.

The members 104 each have a first surface 109a and a second surface 109b. The members 104 may have a uniform thickness T1 (FIG. 3B and FIG. 3C) between the first and second surfaces 109a, 109b. As illustrated in FIG. 2C and FIG. 3E, for example, the adapter 100 may be configured to be positioned and secured in the shaped charge case 201, such that the second surface 109b of each member 104 is adjacent the inner surface 204 of the shaped charge case 201. While the members 104 are illustrated having a substantially rectangular shape, it is contemplated that the members may have any desired shape. For example, it is contemplated that the members 104 may have a generally isosceles trapezoid shape. As described throughout this disclosure, varying geometries of an adapter may produce varying geometries of perforations.

According to an aspect, each member 104 is spaced apart from each other such that the adapter 100 has a central open area 120. The adapter 100 illustrated in FIGS. 2A and 2C, refers collectively to the two members 104 and the central open area 120 refers to the space between the two members 104. When the adapter 100 is positioned in a shaped charge case 201, the central open area 120 is above an initiation point 205 formed in the back wall 215 of the shaped charge case 201. This particular arrangement of the members 104 displaces an explosive load that is housed in the shaped charge case 201 and creates an atypical shape or geometry of a perforating jet and/or perforation produced upon detonation of the shaped charge 200, as described throughout this disclosure.

One or more securing mechanisms 103 may extend from or be otherwise secured to the member 104 and are configured to secure the member 104 to an internal surface (i.e., an internal surface feature 207) of the shaped charge case 201. As used herein, securing mechanisms 103 may include any material that maintains the members 104 in place by friction fit. Securing mechanisms 103 may include clamps, adhesives, clips, welding, or other known techniques. Various configurations of internal surface features 207 are illustrated in FIGS. 2B and 3D.

As illustrated in FIG. 2B, the surface features 207 may be configured as a dimple or a hole formed in the inner surface 204 of the shaped charge case 201. According to an aspect and as illustrated in FIG. 3D and FIG. 3E, the surface feature 207 may be configured as a slotted opening. The surface feature 207 may be arranged at the first or second surfaces 109a, 109b, such that the securing mechanism 103 can be received therein and the members 104 can be secured in the shaped charge case 201.

The securing mechanisms 103 may be positioned at one of a first end 105 and a second end 106 of the member 104. As seen for instance in FIG. 2C, the securing mechanism 103 extends downwardly from the second end 106 of the members 104 and is received in the surface feature 207 of the shaped charge case 201. The securing mechanism 103 may be configured as a protrusion or pin that extends from the second end 106. In an alternate embodiment and as seen in FIG. 3A, the securing mechanism 103 is configured as an elongated protrusion that extends outwardly from the second surface 109b of the member 104. According to an aspect, the elongated protrusion extends from the first end 105 and spans less than 50% the total length of the second surface 109b of the member 104. The elongated protrusion is configured to engage the internal surface feature 207, shown in FIG. 3D and FIG. 3E as a slotted opening, and affix the member 104 to the shaped charge case 201.

With reference to FIGS. 3A-3C, each member 208 is contoured to conform to a contour of the inner surface 204 of the shaped charge case 201. This changes the overall geometry of the hollow interior 203 of the shaped charge case 201 from a rotationally symmetric case to a mirror symmetric case due to the presence of the adapter 202. In other words, the geometry of the hollow interior 203 of the shaped charge case 201 is changed from simply looking the same after the shaped charge has been rotated to a configuration in which one half of the geometry of the hollow interior 203 of the shaped charge case 201 is the mirror image of the other half of the geometry of the hollow interior 203 of the shaped charge case 201. As would be understood by one of ordinary skill in the art, conical shaped charge cases are typically rotationally symmetric, while slotted/rectangular shaped charge cases are typically mirror symmetric. When installed in the shaped charge case 201, the members 208 are arranged such that the open area 120 between the members 208 is disposed over the initiation point 205 of the shaped charge case 201, as described above with respect to the central open area 120 of the adapter 100 shown in FIG. 2.

FIG. 3B shows one member of the plurality of members 104 from the first end 105. FIG. 3C shows one member of the plurality of members 104 from the second end 106. In both views, the members 104 have a uniform thickness T1. According to an aspect, each of the plurality of members 104 may be configured with a uniform thickness T1 or a non-uniform thickness (not shown) between the first end 105 and the second end 106.

FIG. 4A and FIG. 4B illustrate the adapter 100 being positioned in a shaped charge 200. The shaped charge includes a shaped charge case 201 having a hollow interior 203. The adapter is positioned in the hollow interior 203 and its securing mechanisms 103 are secured to an inner surface 204 of the shaped charge case 201. Each member 104, configured substantially as described hereinabove with respect to FIG. 2A, FIG. 2C, FIGS. 3A-3C and FIG. 3E, is arranged in a spaced apart configuration from another member 104. This arrangement of the members 104 creates a central open area 120 of the adapter 100.

An explosive load 230 is disposed on top of the adapter 100 and substantially fills the central open area 120. The explosive load 230 extends along at least a portion of a back wall 215 of the shaped charge case 201, and over an initiation point 205 formed in the back wall 215. The initiation point 205 may be an aperture or depression formed in the back wall 215 of the shaped charge case 201. When a detonating cord positioned adjacent the initiation point 205 is initiated, a detonation wave (or initiation energy produced upon initiation of the detonating cord) travels along the detonating cord to the initiation point 205, and ultimately to explosive load 230 (including explosive powder) housed in the shaped charge case 201.

A liner/conical liner 240 is positioned over the explosive load. When the shaped charge 200 is initiated, the explosive load 230 detonates and creates a detonation wave that causes the liner 240 to collapse and be expelled from the shaped charge case 201. The expelled liner 240 produces a forward-moving perforating jet that moves at a high velocity. The resulting perforating jet, the shape of which is altered due to the displacement of some of the explosive load 230 by the adapter 100, creates an atypical perforation hole in a target relative to a substantially similar shaped charge without an adapter.

As described in further detail hereinbelow, the atypical perforation hole may be a slotted or elliptical perforation hole. As described hereinabove, elliptical or slotted perforations may be particularly useful in forming overlapping rectangular slots to allow full 360-degree access through a wellbore casing to flow concrete and seal a wellbore upon abandonment. In addition, the elliptical or slotted perforations are flow optimized and may be ideal for fracturing applications, which include the injection of fluid into the underground formation to force open cracks or fissures in the formation. This helps to reduce the breakdown pressure of a formation. The elliptical or slotted perforations may overlap each other in a helical pattern, thereby facilitating the 360° perforation of a cylindrical target. It is contemplated that the atypical perforation hole may have other shapes, at least based in part by the quantity of members 104, as described in further detail hereinbelow.

FIG. 4B illustrates the securing mechanisms 103 extending from a top portion of the adapter 100, as opposed to extending from a bottom portion of the adapter 100 as shown in FIG. 4A. It is contemplated that securing mechanisms 103 may extend from the top portion and the bottom portion of the adapter 100, as well as any position between the top portion and the bottom portion.

FIG. 5 illustrates a perspective view of another configuration of an adapter 100 for use with a shaped charge. The adapter 100 may be particularly suited for being secured within a hollow interior of a shaped charge case. According to an aspect and as described hereinabove with respect to FIGS. 2A and 3A, the adapter 100 may be formed from an inert material that does not react with the materials/components of the shaped charge.

The adapter 100 includes a collar 102 and a plurality of members 104a, 104b (also referred to collectively as members 104) extending from or otherwise secured to the collar 102 in a spaced apart configuration from each other. The collar 102 and the members 104 may be 3D printed, injection molded or machined. According to an aspect, the collar and members may be formed of the same materials or may be formed together as a single structure. The collar 102 couples the plurality of members 104 and maintains the members 104 in a spaced apart configuration from each other, such that when the adapter 100 is inserted into a shaped charge case, the collar 102 maintains the position of the members 104 in the shaped charge case. The members 104 may be configured substantially as illustrated in FIGS. 2A, 2C, 3A-3C and 3E and described hereinabove, thus for purposes of convenience and not limitation, the various features of the members 104 are not repeated here.

According to an aspect, the collar 102 and the plurality of members 104 are configured for being secured to an inner surface of the shaped charge case. As illustrated in FIG. 5, for example, the members 104 are arranged on the collar 102 so that the adapter 100 has a central open area 120. The central open area 120 allows explosive powder/explosive load used in shaped charges to fill the space in between the members 104 to facilitate formation of a detonation wave (described in detail hereinabove with respect to FIGS. 4A-4B).

Each of the plurality of members 104a, 104b has a first end 105 and a second end 106 spaced apart and opposite from the first end 105. The collar 102 may be secured to a substantially central portion 107 of each member 104a, 104b, between the first and second ends 105, 106. According to an aspect, the collar 102 may extend from or be otherwise secured to any desired position along the length of the members 104a, 104b. As used herein, first end, second end, central portion, and other descriptions related to relative locations on the exemplary members described throughout this disclosure are for aiding in the description of the associated configurations and do not limit or constitute limiting delineations of any portion(s) of the exemplary members/adapters, unless otherwise indicated.

The size of the collar 102 and the size of the members 104 may be selected based on the needs of the application in which the shaped charge they are secured to will be used. According to an aspect, the collar 202 and members 104 may be sized according to the internal diameter of the shaped charge case in which they are to be secured. Each of the plurality of members 104 may span about 20 degrees to about 100 degrees of a circumference of the collar 102. According to an aspect, each member 104 spans 60 degrees of the circumference of the collar 102.

According to an aspect, the members include a first member 104a and a second member 104b. The first and second members 104a, 104b may be spaced 180 degrees away from each other on the collar 102 (i.e., when measurements are taken from the central portion of the width of each member 104). According to another exemplary embodiment, the members 104a, 104b may be spaced, e.g., 90 degrees away from each other on the collar 102. While two members 104 are shown, it is contemplated that an embodiment may include more than 2 members.

According to an aspect, the adapter 100 is a symmetrical adapter by virtue of each member (such as two members 104a, 104b) being mirror images and equally spaced apart from each other on the collar 102. Each of the plurality of members 104 may be configured with a uniform thickness T1 (FIG. 3B) or a non-uniform thickness (not shown) between the first end 105 and the second end 106. According to an aspect, when the members 104 have a non-uniform thickness, the thickness of the substantially central portion 107 of the members 104 is greater than the thickness of the first end 105 and greater than the thickness of the second end 106. This may help to ensure that that the members 104 are properly secured to the collar 102, when the collar 102 and the members 104a, 104b are formed as two separate structures.

Further embodiments of the disclosure are associated with a shaped charge/conical shaped charge 200 configured to create atypical perforation hole geometries in a target. FIGS. 6A, 6B and 6C illustrate top views of the shaped charge 200, in accordance with an embodiment. The shaped charge 200 includes a shaped charge case 201 formed from at least one of machinable steel, aluminum, stainless-steel, copper, zinc, and the like. As illustrated in FIG. 6A, the shaped charge case 201 has an initiation point 205 formed in a back wall 215 of the case 201.

According to an aspect, an inner surface 204 of the shaped charge case 201 defines an overall geometry of a hollow interior 203 (FIG. 6A) of the shaped charge case 201. The hollow interior 203 is configured to house one or more of an adapter/insert/internal inlay 202, the explosive material 230, and a liner 240 (FIG. 6A). The use of the exemplary shaped charges 200 and adapters 100, 202 may also aid in the reduction of gun swells (often leading to total loss of the perforating gun and the shaped charges secured therein), by virtue of the partial replacement of explosive and, consequently, a reduction of the explosive energy of the shaped charge. The reduction of the explosive energy generates less pressure, which reduces the well of a perforating gun.

According to an aspect, the inner surface 204 of the shaped charge case 201 defines a conical or substantially frustoconical interior volume and the overall shape and volume of the hollow interior 203 of the shaped charge case 201 is modified by the adapter 202. The shaped charge 200 includes the adapter 202 secured to the inner surface 204 of the shaped charge case 201. The adapter 202 includes a collar 206 and a plurality of members 208 extending from or otherwise secured to the collar 206 in a spaced apart configuration from each other. In this arrangement, the members 208 are disposed about the collar 206, such that the adapter 202 has a central open area 220.

FIGS. 6A-6B and FIGS. 7A-7B, for example, illustrate an adapter 202 housed within the hollow interior 203 and secured to the inner surface 204 of the shaped charge case 201. The adapter 202 is configured substantially as the adapter 100 described hereinabove and illustrated in FIG. 5. Thus, for purposes of convenience and not limitation, similar features of the adapter 100 illustrated in FIG. 2 and the adapter 202 are not repeated hereinbelow.

As illustrated in FIG. 6A, the adapter 202 includes a collar 206. A plurality of members 208 (FIG. 4A) extend from or are otherwise secured or otherwise coupled to the collar 206. The adapter 202 may be coupled to the inner surface 204 of the shaped charge case 201 by, for example and without limitation, adhesives, or may be rigidly secured in place within the inner surface by friction fit, clamps, adhesives, clips, welding, or other known techniques. It is contemplated that the adapter 202 may be secured in the shaped charge case 201 by virtue of the additional components of the shaped charge (explosive load, liner, and the like) being pressed on top of the adapter 202. According to an aspect, the collar 206 may be frictionally secured to the inner surface 204 of the shaped charge case 201, while the members 208 are not separately secured to the shaped charge case 201. In an embodiment, at least one of the collar 206 and the plurality of members 208 are affixed to the inner surface 204 of the shaped charge case 201 by an adhesive or by securing mechanisms, such as a protrusion or pin that extends from one or each member 208. Such securing mechanisms may be configured substantially as described hereinabove with respect to FIGS. 2A, 2C, 3A-3C and 3E, thus for purposes of convenience and not limitation, those securing mechanisms are not repeated here.

FIG. 6B and FIG. 6C illustrate an explosive load 230 disposed in/received within the hollow interior 203 of the shaped charge case 201. The explosive load 230 is in direct contact with at least a portion of/certain areas of the inner surface 204 of the shaped charge case 201. In these configuration(s), the adapter 202 is adjacent to other portions of the inner surface 204 of the shaped charge case 201 so that it effectively displaces the explosive load 230 that would otherwise occupy those spaces. For example, at least a portion of the members 208 displaces a portion of the explosive load 230 that would otherwise occupy the volume occupied by the members 208 within the hollow interior 203 of the shaped charge case 201. The collar 206 may also displace a portion of the explosive load 230. In manufacturing such a shaped charge 200, it is expected that less explosive material will be required, which may help reduce costs associated with manufacturing the shaped charge.

The portion(s) of the adapter 202 that displace some of the explosive load 230 defines a shape and a corresponding distribution of the explosive load 230 that, upon detonation of the shaped charge 200, produces an atypical perforating jet geometry and resultant perforation hole geometry as compared to a perforating jet/perforation hole geometry produced by the shaped charge 200 in the absence of the adapter 202. For example, the typical conical shaped charge 10 (FIG. 1A) without an adapter produces the round perforation hole 50 shown in FIG. 1C. On the other hand, the conical shaped charge 200 including the adapter 202 as shown in FIG. 6A, having two members 208, produces an elongated perforation hole geometry. Such elongated perforation hole geometry may be an elliptical perforation hole 300 (e.g., as shown in FIG. 8A) or a slotted-type perforation hole 400 (e.g., as shown in FIG. 8B) despite the case 201 having a substantially similar geometry as the case 20 of the typical conical shaped charge 10. The shape of the perforation hole may depend on the distance between the shaped charge and the target/target formation. For instance, a first shaped charge 200 (including adapter 202) that is close to the target results in an elliptical perforation hole 300, while a second shaped charge 200 that is further away from the target that the first shaped charge results in a rectangular perforation hole. It is contemplated that shaped charges 200 positioned at distances greater than the distance of a second shaped charge may result in a perforation hole that is substantially rectangular, and includes a waisted portion at a central distance along the length of the rectangular perforation hole. The elliptical or slotted perforation hole is useful in forming overlapping rectangular or linear slots to allow full 360-degree access through a wellbore casing to flow concrete and seal a wellbore upon abandonment. As described hereinabove, the elliptical or slotted perforation hole may be suitable for hydraulic fracturing applications.

According to an aspect, the explosive load 230 may include a first layer/first explosive layer 232 of explosive and a second layer/second explosive layer 234 of explosive. The first explosive layer 232 may be disposed adjacent the back wall 215 and initiation point 205 of the shaped charge 200, as well as at least a portion of the adapter 202. The first explosive layer 232 may be more sensitive to initiation than the second explosive layer 234.

As illustrated in FIG. 6B, for example, a first layer 232 of the explosive load 230 covers a portion of the adapter 202. At least a portion of the members 208 are still visible. According to an aspect, the first layer 232 is disposed over the adapter 202 so that it at least partially covers the adapter 202 and the second layer 234 of explosive is loosely disposed on top of the first layer 232 so that it fully covers the adapter 234. Both layers 232, 234 may be pressed together onto the adapter 202. According to an aspect, the first and second layers 232, 234 may be separately pressed onto the adapter once they are disposed in the shaped charge case 201.

FIG. 6C illustrates that the second layer 234 of explosive may be disposed on top of the first layer 232 of explosive and pressed onto the first layer 232 to ensure that there are no gaps between the explosive load 230 and the adapter 202. Pressing any one of the first and second layers 232, 234 helps to ensure that the explosive load is properly distributed in the hollow interior 203 of the case 201, in order to facilitate the collapse of a liner disposed on top of the explosive load 230 and penetration of a resulting perforating jet into a target or formation. According to an aspect, the second layer 234 of explosive load may help to ensure that the first layer 232 remains in place, however, the adapter 202 will still affect the general configuration of the explosive load 230 in the shaped charge case 201 and the shaped charge will still result in an atypical perforation shape (such as an elliptical or slotted perforation).

According to an aspect, the explosive load 230 includes a plurality of powders. Such powders may include at least one of pentaerythritol tetranitrate (PETN), cyclotrimethylenetrinitramine (RDX), octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine/cyclotetramethylene-tetranitramine (HMX), 2,6-Bis(picrylamino)-3,5-dinitropyridine/picrylaminodinitropyridin (PYX), hexanitrostibane (HNS), triaminotrinitrobenzol (TATB), and PTB (mixture of PYX and TATB). According to an aspect, the explosive load 230 includes diamino-3,5-dinitropyrazine-1-oxide (LLM-105). The explosive load 230 may include a mixture of PYX and triaminotrinitrobenzol (TATB). The type of explosive material used may be based at least in part on the operational conditions in the wellbore and the temperature downhole to which the explosive may be exposed. According to an aspect, the first layer 232 and the second layer 234 of explosive load may include the same type of explosive material or explosive powder. According to an aspect, the first layer 232 includes at least one of HNS, LLM-105, PYX, and TATB, while the second layer 234 includes a binder and at least one of HNS, LLM-105, PYX, and TATB.

According to an aspect, and as illustrated in FIG. 7A, the shaped charge 200 includes a pre-pressed liner/pressed metal powder/conical liner 240 disposed atop the explosive load 230. The general shape of the conical liner 240 is illustrated in FIG. 7A. As would be understood by one of ordinary skill in the art, the liner 240 may be formed from a variety of powdered metallic and non-metallic materials and/or powdered metal alloys, and binders. According to an aspect, the liner 240 is formed from copper, pressed to form the desired liner shape. In certain exemplary embodiments, the liner material(s) may include an inert material, where an inert material may be a material that does not participate in a chemical reaction, including an exothermic chemical reaction, with the liner 240 and/or other components of the shaped charge including elements created as a result of a detonation of the shaped charge. In the same or other embodiments, the liner material may include an energetic material, where an energetic material may be a material that is capable of a chemical reaction, including an exothermic chemical reaction, with one or more components of the liner 240 and/or other components of the shaped charge including elements created as a result of a detonation of the shaped charge. Typical liner constituents and formation techniques are further described in commonly-owned U.S. Pat. No. 9,862,027, which is incorporated by reference herein in its entirety to the extent that it is consistent with this disclosure. When the shaped charge 200 is initiated, the explosive load 230 detonates and creates a detonation wave that causes the liner 240 to collapse and be expelled from the shaped charge case 201. The expelled liner 240 produces a forward-moving perforating jet that moves at a high velocity. The resulting perforating jet, the shape of which is altered due to the displaced explosive load 230, creates an atypical perforation hole in a target.

According to an aspect and as illustrated in FIG. 7B, the explosive load 230 is not uniformly distributed within the hollow interior 203 of the shaped charge case 201 due to the presence of the adapter 202. Thus, different magnitudes of explosive force may be generated at different locations within the hollow interior 203 depending on the amount of explosive at a particular location. The geometry of the perforating jet and resulting perforation are, at least in part, a function of the distribution of these explosive forces. As such, adapters 100, 202 according to this disclosure may be particularly designed for distributing an explosive load/explosive force profile to achieve to a desired perforation geometry, such as the slot or elliptical shaped geometry formed as a result of two members secured to the inner surface 204 of the shaped charge case 201 in a spaced apart distance from each other.

FIG. 8A and FIG. 8B illustrate an exemplary perforation shape generated by the shaped charge 200 including the adapter 202 and the conical liner 240. Upon detonation of the shaped charge 200, the liner 240 is expelled out of the shaped charge case 201 in a partially deformed configuration (or jet of material) relative to the expelled configuration of the same liner in a shaped charge without the adapters 100/202 disclosed herein. As illustrated in FIG. 8A, the perforation shape is altered from that of a standard round perforation hole and may result in an elliptical shape 300.

According to an aspect an as illustrated in FIG. 8B, the perforation shape is altered from that of a standard round perforation hole and may result in a slot/rectangular shape 400 perforation/entrance opening in a casing/target.

FIGS. 9A-9C schematically illustrate various views of the components of the shaped charge 200. FIG. 9A illustrates an assembled shaped charge 200 having the liner 240 secured within the shaped charge case 201. While not visible in the assembled shaped charge 200 illustrated in FIG. 9A, an adapter and explosive load is housed in a hollow interior of the shaped charge case 201.

FIG. 9B illustrates the general arrangement of the liner 240 when disposed atop the explosive load 230, and the explosive load 230 when disposed atop the adapter 202.

FIG. 9C illustrates the general arrangement of illustrates an isolated view of the adapter 202. As described in detail hereinabove, the adapter 202 includes a collar 206 and two members 208a, 208b (collectively members 208) coupled or otherwise secured to the collar 206.

FIG. 10 illustrates a side view of a conical shaped charge 200. While not shown in FIG. 10, the conical shaped charge 200 includes the adapter 202, explosive load and liner 240 described hereinabove and illustrated in FIG. 7A.

FIG. 11A is a cut through view of the shaped charge 200 of FIG. 10. At least a portion of the explosive load 230 is adjacent the inner surface 204 of the case 201, while remaining amounts of the explosive load 230 are adjacent only the adapter 202. As described hereinabove, the inner geometry of the shaped charge 200 is changed from a rotational symmetric inner contour to a mirror symmetric contour due to presence of the adapter 202 which has a plurality of members in a mirror symmetric contour as previously discussed.

FIGS. 11B-11D illustrate additional cut through views of the shaped charge of FIG. 10 and illustrate that the thickness of the members of the adapter may vary along its length. As illustrated in FIG. 11B, the first end/upper end 209 of each member 208a, 208b may have a thickness that is less than a thickness of the substantially central portion 211 (i.e., the region closest to the collar 206) (FIG. 11C) of the respective member 208a, 208b.

Similarly, as illustrated in FIG. 11D, a thickness of the second end 210 of each member 208a, 208b may be less than the thickness of the substantially central portion 211 (FIG. 11C) of the respective member 208a, 208b. The second ends 210 of the members 208 are closest to the apex 242 of the liner 240 and surrounded by the largest quantity of explosive load 230. According to an aspect, this allows the explosive force generated upon initiation of the shaped charge to be highest at the central open area of the adapter 202 and generally at the positions of the collar 206 (FIG. 6C) that do not accommodate members 208.

FIGS. 12A-12C illustrate top views of shaped charges 200 having adapters 202 secured therein. Each adapter 202 is illustrated as having members 208 with different cross-sectional shapes. FIG. 12A illustrates members 208 having a crescent-shaped cross-section.

FIG. 12B illustrates members 208 having a substantially planar cross-section on a first side 213a and a curved surface on an opposite, second side 213b that adapts to the contours of the inner surface 204 of the shaped charge case 201.

FIG. 12C illustrates members 208 having a substantially rectangular or block-shaped cross-section. The general shape and various dimensions of the members 208 may be adapted to create a wide variety of perforating geometries for particular applications and sizes of shaped charge cases in which the adapter 202 is to be secured.

According to an aspect, a detonating device, such as a detonating cord or a booster, may be in contact or communication with the explosive load 230 through an initiation point formed in the back wall/closed end of the shaped charge case 201, to initiate detonation of the shaped charge 200. According to an aspect, the initiation point may be an aperture or depression formed in the back wall. When the detonating cord is initiated, a detonation wave (or initiation energy produced upon initiation of the detonating cord) travels along the detonating cord to the initiation point, and ultimately to the explosive load 230. The explosive load 230 detonates and creates a detonation wave, which generally causes the liner 240 to collapse and be ejected from the case 201, thereby producing a forward moving perforating jet. The adapter 202 secured to the inner surface 204 of the shaped charge case 201 impacts the shape of the perforating jet by interfering with the detonation/ballistic wave in a manner that produces an atypical perforation hole geometry in a target. Such atypical perforation hole geometries may be a slot/rectangular hole formed by a conical shaped charge, rather than the typical circular perforation hole geometry formed when conical shaped charges are initiated without an adapter. It is contemplated that more than two members may be included on the collar of the adapter, which may result in other perforation hole geometries. According to an aspect, an adapter including three members spaced apart from each other may form a triangle-shaped perforation hole geometry, an adapter including four members spaced apart from each other may form an X-shaped perforation hole geometry, an adapter including five members spaced apart from each other may form a star-shaped perforation hole geometry, and an adapter including six members spaced apart from each other may form a daisy-shaped perforation hole geometry.

FIG. 13 illustrates a cross-section view of a shaped charge 1300. The shaped charge 1300 includes a shaped charge case 1302 having a back wall 1322 and at least one side wall 1324. According to an aspect, the shaped charge case 1302 further includes a hollow interior 1320 that is bounded by the back wall 1322 and the at least one side wall 1324. According to an aspect, a detonating cord receptacle 1310 extends from the back wall 1322. The detonating cord receptacle 1310 is configured to receive and guide at least a portion of a detonating cord along the back wall 1322 of the shaped charge case 1302.

An adapter 1304 is positioned in a hollow interior 1320 of the shaped charge case 1302. The adapter includes a plurality of members 1312. The plurality of members 1312 each extend along a portion of an inner surface 1314 of the shaped charge case 1302. A surface profile of each of the plurality of members 1312 is contoured to conform to a contour of the inner surface 1314 of the shaped charge case 1302. Each member of the plurality of members 1312 include a first surface 1326 and a second surface 1328 spaced apart from the first surface 1326. According to an aspect, the second surface 1328 is configured to be adjacent the inner surface 1314 of the shaped charge case 1302. Each member of the plurality of members 1312 is configured to be secured to the inner surface 1314 of the shaped charge case 1302. Each member may include a securing mechanism 1318 that aids in securing the member within the hollow interior 1320. According to an aspect, each member of the plurality of members 1312 is spaced apart from each other such that the adapter 1304 has a central open area 1316.

According to an aspect, an explosive load 1306 is positioned in the shaped charge case 1302 on top of the plurality of members 1312 (i.e., the adapter 1304). Since each member of the plurality of members 1312 is spaced apart from each other, at least some of the explosive load 1306 extends along the inner surface 1314 of the shaped charge case 1302.

A liner 1308 is illustrated as being positioned on top of the explosive load 1306. The liner 1308 may be configured as a pre-pressed liner/pressed metal powder/conical liner that is disposed atop the explosive load 1306. According to an aspect, the liner 1308 is configured substantially as illustrated in FIG. 7A and described hereinabove.

FIG. 14 illustrates a partial cutaway view of a shaped charge 1300 including the adapter 1304. In this configuration of the adapter 1304, an additional mode of securing the plurality of members 1312 in the hollow interior 1320 of the shaped charge case 1302 is shown. The additional mechanism includes a protrusion 1402 that extends outwardly from the second surface 1328 of the member. While the protrusion 1402 is illustrated in FIG. 14 as having a generally rectangular shape, it is contemplated that the protrusion 1402 may have any shape that can help to secure it in the hollow interior 1320. For example, as show in FIG. 16, the protrusion 1402 may have an elliptical shape.

FIG. 15 is a top down, perspective view of an adapter 1304 including a ring structure. The ring structure includes a collar 1506, according to an embodiment. A pair of members 1312 are illustrated as being secured to the collar 1506 in a spaced apart configuration from each other such that the adapter 1304 includes a central open area 1316. The plurality of members 1312 may include a first member 1504 and a second member 1502. According to an aspect, the first member 1504 is spaced apart from the second member 1502 by 180 degrees, as measured in relation to a circumference of the collar 1506.

According to an aspect, a width of each of the first member 1504 and the second member 1502 spans between approximately 20 degrees to 100 degrees of a circumference of the collar 1506. According to an aspect, the total width of the first member 1504 and the second member 1502 may span about 120-degrees to about 180-degrees of a total circumference of the shaped charge case. According to an aspect, the width of each of the first member 1504 and the second member 1502 is about 5 mm to about 65 mm.

According to an aspect, the collar 1506 and the plurality of members 1312 are both secured to the inner surface 1314 of a shaped charge case 1302. According to an aspect, the collar 1506 is used to arrange or position the plurality of members 1312 of the adapter 1304 in the opposite direction from each other to help secure the adapter 1304 within the hollow interior 1320 of the shaped charge case 1302. The plurality of members 1312 of the adapter 1304 may be fixed in relation to each other, or they may be slidably positioned on the collar 1506. According to an aspect, at least one of the collar 1506 and the plurality of members 1312 are secured to the inner surface 1314 of the shaped charge case 1302 via an adhesive, clips, welding, and the like. According to an aspect, at least one of the collar 1506 and the plurality of members 1312 are secured to the inner surface 1314 of the shaped charge case 1302 via a plug connection, friction or a securing member.

The adapter 1304 is formed from an inert material that does not participate in a chemical reaction. The inert material will not participate in an exothermic chemical reaction, with the liner 240 and/or other components of the shaped charge including elements created as a result of a detonation of the shaped charge. According to an aspect, the adapter 1304 may be formed of similar materials as the adapter 100 described hereinabove.

With reference to FIG. 16, which is a bottom, perspective view of the adapter 1304, the first member 1504 and the second member 1502 may each include a first end portion 1602 and a second end portion 1608 opposite and spaced apart from the first end portion 1602, with the collar extending from a substantially central portion of each of the first member 1504 and the second member 1502, between the first end portion 1602 and the second end portion 1608.

The protrusions 1402 are illustrated as extending from the second surface 1328 (FIG. 13) to help fixate the adapter 1304 in the shaped charge case 1302. Each protrusion 1402 extends in an outward direction, away from the central open area 1316. In this configuration, the protrusions 1402 engage with an inner surface 1314 of the shaped charge case 1302 illustrated in FIG. 13.

According to an aspect, each member of the plurality of members 1312 has a first end portion 1602 and a second end portion 1608 opposite and spaced apart from the first end portion 1602. The second end portion 1608 of the first member 1504 may have a contoured end 1604 and the second end portion 1608 of the second member 1502 may also have a contoured end 1610. Both contoured ends 1610, 1604 may be shaped so that they generally frame the initiation point 1702 (shown, e.g., in FIG. 18) of the shaped charge 1300 within which they are positioned. It is contemplated that this will help to ensure that appropriate detonation of the shaped charge 1300 will occur since the initiation point 1702 (FIG. 17) of the shaped charge 1300 will be in line with the explosive load 1306 disposed in the shaped charge case 1302.

FIG. 17 illustrates the adapter 1304 illustrated in FIG. 16 as being positioned and secured in the shaped charge case 1302. The contoured ends 1610, 1604 of the second end portion 1608 of the first member 1504 and the second end portion 1608 of the second member 1502 are illustrated as flanking the initiation point 1702 of the shaped charge 1300. As described herein above, this ensures that the explosive load 1306 fills the central open area 1316 and the initiation point 1702 is in contact with the explosive load 1306.

FIG. 17 also shows the collar 1506 extending between the first member 1504 and the second member 1502. The collar 1506 both joins and helps to space the first member 1504 and the second member 1502 apart from each other. While the first member 1504 and the second member 1502 are shown as being equidistantly spaced apart from each other, it is contemplated that they may be closer together on a first side of the collar 1506 than on another opposite side of the collar 1506.

FIG. 18 illustrates that the shaped charge case 1302 may be modified to receive and secure the adapter 1304 within its hollow interior 1320. For example, each shaped charge case 1302 includes an internal surface feature 1802. The internal surface feature 1802 may be configured as an indentation or groove formed in the inner surface 1314 of the shaped charge case 1302. According to an aspect, the internal surface feature 1802 is a dug-out portion of the inner surface 1314 of the shaped charge case 1302 or it may be formed during the process of forming the shaped charge case 1302.

As described hereinabove and illustrated at least in FIG. 17, the securing mechanisms 1318 may extend outwardly from the second surface 1328 of the plurality of members 1312 to engage the internal surface feature 1802. In other words, the internal surface features 1802 may be configured to receive the protrusions 1402 of the adapter 1304. The internal surface features 1802 may serve as the lock-in points for the protrusions 1402. According to an aspect, the internal surface feature 1802 may be configured a receptacles for the securing mechanisms 1318. The internal surface feature 1802 may be configured as at least one of a dimple, a hole and a slotted opening.

According to an aspect, the internal surface features 1802 may include a shoulder or ledge 1804 upon which the collar 1506 of the adapter 1304 is positioned. The ledge 1804 may be configured to serve as a stop point for the placement of the adapter 1304 in the hollow interior 1320 of the shaped charge case 1302. This may help to ensure that the plurality of members 1312 do not get over-inserted into the hollow interior 1320 of the shaped charge case 1302.

As illustrated in FIG. 19, the initiation point 1702 is an opening that is bored through the shaped charge case 1302. The initiation point 1702 may be a space in the back wall 1322 of the shaped charge case 1302 that was formed during the manufacturing process. According to an aspect, the initiation point 1702 may include a dug out portion of the back wall 1322 of the shaped charge case 1302. The internal surface features 1802 are illustrated as receptacles shaped as ellipsis that are configured to receive the securing mechanisms 1318 of the adapter 1304.

FIG. 20 is a partial cut-away view of a shaped charge 1300 having an inner surface 1314 that defines a hollow interior 1320 of the shaped charge case. According to an aspect, the shaped charge 1300 includes an adapter 1304 coupled to the inner surface of the shaped charge case 1302. The adapter 1304 includes a plurality of members (see, for example, first member 1504) secured to the inner surface in a spaced apart configuration from each other, such that the adapter has a central open area 1316. Each adapter may be coupled to or otherwise extend from a collar 1506.

An explosive load 1306 is disposed within the hollow interior 1320 atop the adapter 1304, such that the explosive load 1306 covers a substantial portion or all of the adapter 1304 and is in direct contact with a portion of the inner surface 1314 of the shaped charge case 1302. According to an aspect, the explosive load 1306 is configured to produce a perforating jet upon detonation of the shaped charge 1300. As illustrated in FIG. 20, the shaped charge 1300 may also include a liner 1308 disposed on top of the explosive load 1306. At least a portion of the adapter 1304 displaces some of the explosive load 1306 such that, upon detonation of the shaped charge 1300, a perforation with an atypical geometry based at least in part by shape of the shaped charge case 1302 and the shape of the liner 1308, is produced.

The shaped charge case includes a detonating cord receptacle 1310 arranged about the initiation point of shaped charge case 1302. According to an aspect, the detonating cord receptacle 1310 includes a first cord slot 1810 (FIG. 21) for receiving and arranging at least a portion of a detonating cord along the initiation point 1702 and routing the detonating cord within a perforating gun housing.

FIG. 21 is a perspective view of a shaped charge case including a guide 1814 formed in the outer surface of the shaped charge case 1302. According to an aspect, the guide 1814 extends along the side wall 1324 (FIG. 13) of the shaped charge case 1302 and is configured to receive at least a portion of the detonating cord. The guide 1814 may include a groove that is parallel to a longitudinal axis of the shaped charge case 1302. According to an aspect, the guide 1814 may include at least two guides 1814. The at least two guides 1814 are spaced apart from each other so that they provide alternate routes for placement and positioning of a detonating cord. For example, FIG. 21 illustrates the guides 1814 being two (2) spaced apart grooves 1810, 1812 formed in the external surface of the shaped charge case 1302. While the grooves 1810, 1812 are shown as being equidistantly spaced, other arrangements are contemplated.

FIGS. 22-26 illustrate views of perforation holes that may be formed with a shaped charge including an adapter. FIG. 22 illustrates a perforation that is not a typical round hole, but is that of an atypical perforation 2202 that was generated upon detonation of a conical shaped charge.

FIG. 23 illustrates a generally rectangular or slotted atypical perforation 2202 generated upon detonation of a conical shaped charge.

FIG. 24 illustrates a generally square atypical perforation 2202 generated upon detonation of a conical shaped charge.

FIG. 25 illustrates a generally rectangular-shape atypical perforation 2202 generated upon detonation of a conical shaped charge.

It is further contemplated that due to the displacement of explosive load by the adapter and/or the reduced amount of explosive load in the shaped charge case due to the presence of the adapter, the potential gun swell of perforating guns that include a modified shaped charge (in accordance with the disclosure herein) is smaller than the gun swell that is seen with standard shaped charges. This may be particularly beneficial on wells with limitations to the perforating gun housing's outer diameter.

The present disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems and/or apparatus substantially developed as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present disclosure after understanding the present disclosure. The present disclosure, in various embodiments, configurations and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.

The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms “a” (or “an”) and “the” refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Furthermore, references to “one embodiment”, “some embodiments”, “an embodiment” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as “first,” “second,” “upper,” “lower” etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.

As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”

As used in the claims, the word “comprises” and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, “consisting essentially of” and “consisting of.” Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that variations in these ranges will suggest themselves to a practitioner having ordinary skill in the art and, where not already dedicated to the public, the appended claims should cover those variations.

The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the present disclosure are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the present disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the present disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, the claimed features lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present disclosure.

Advances in science and technology may make equivalents and substitutions possible that are not now contemplated by reason of the imprecision of language; these variations should be covered by the appended claims. This written description uses examples to disclose the method, machine and computer-readable medium, including the best mode, and also to enable any person of ordinary skill in the art to practice these, including making and using any devices or systems and performing any incorporated methods. The patentable scope thereof is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A shaped charge comprising: a shaped charge case comprising an inner surface and an outer surface, wherein the inner surface defines a hollow interior of the shaped charge case;an adapter coupled to the inner surface of the shaped charge case, the adapter comprising: a collar; anda plurality of members secured to the collar in a spaced apart configuration from each other such that the adapter has a central open area;an explosive load disposed within the hollow interior atop the adapter, such that the explosive load covers the adapter and is in direct contact with a portion of the inner surface of the shaped charge case; anda liner disposed adjacent the explosive load, wherein at least a portion of the adapter displaces some of the explosive load, andthe displaced explosive load is configured to accelerate the liner to produce a perforating jet upon detonation of the shaped charge such that the adapter is configured to produce an atypical perforation hole geometry in a target.

2. The shaped charge of claim 1, wherein the plurality of members comprises: a first member; anda second member,wherein the first and second members are spaced 180 degrees from each other on the collar.

3. The shaped charge of claim 2, wherein a width of each of the first member and the second member spans between approximately 20 degrees to 100 degrees of a circumference of the collar.

4. The shaped charge of claim 1, wherein each of the plurality of members comprise a first end and a second end opposite and spaced apart from the first end, wherein the collar is secured to a substantially central portion of each of the members between the first and second ends.

5. The shaped charge of claim 4, wherein, in each member of the plurality of members, a thickness of the first end is less than a thickness of the corresponding substantially central portion.

6. The adapter of claim 4, wherein, in each member of the plurality of members, a thickness of the second end is less than a thickness of the corresponding substantially central portion.

7. The adapter of claim 4, wherein, in each member of the plurality of members, a thickness of the substantially central portion is greater than a thickness of the first end and greater than a thickness of the second end.

8. The shaped charge of claim 1, wherein a surface profile of each of the plurality of members is contoured to conform to a contour of the inner surface of the shaped charge case.

9. The shaped charge of claim 1, wherein the adapter is formed from a plastic material.