Alignment sub and perforating gun assembly with alignment sub

Abstract

A perforating gun assembly may include a first perforating gun housing, a first shaped charge provided within the first perforating gun housing, and an alignment sub coupled to the first perforating gun housing. The alignment sub may include a first sub body and a second sub body rotatably coupled to the first sub body.

Description

BACKGROUND OF THE DISCLOSURE

Wellbore tools used in oil and gas operations, including perforation guns housing shaped charges, are often sent down a wellbore in tool strings connected together to reduce time and costs associated with the operation. Sub-assemblies connect adjacent wellbore tools to one another to form the tool string.

Hydraulic fracturing produces optimal results when perforations are oriented in the direction of maximum principle stress or the preferred fracture plane (PFP). Perforations oriented in the direction of the PFP create stable perforation tunnels and transverse fractures (perpendicular to the wellbore) that begin at the wellbore face and extend far into the formation. However, if fractures are not oriented in the direction of maximum stress, tortuous, non-transverse fractures may result, creating a complex near-wellbore flow path that can affect the connectivity of the fracture network, increase the chance of premature screen-out, and impede hydrocarbon flow. A wellbore tool string including perforating guns may frequently rest on a lower horizontal surface of a wellbore casing. This positioning may result in larger perforations being formed by shaped charges oriented toward the nearby horizontal surface, and smaller perforations being formed by shaped charges oriented away from the nearby horizontal surface.

Accordingly, there is a need for an alignment sub that allows alignment of the phasing of shaped charges in two or more adjacent perforation guns connected on a tool string. Further, there is a need for an orienting alignment sub assembly for orienting a wellbore tool with aligned shaped charges in a wellbore so consistently sized perforations may be formed by shaped charges oriented in different directions.

BRIEF DESCRIPTION

An exemplary embodiment of an alignment sub may include a first sub body, a bulkhead body, a first bulkhead pin and a second bulkhead pin, a bulkhead retainer, and a second sub body. The first sub body may have a first sub body first end and a first sub body second end opposite the first sub body first end. The first sub body may include a first sub body first inner surface, a first sub body second inner surface, and a first sub body recess wall. T first sub body first inner surface may define a first sub body first bore extending from the first sub body second end towards the first sub body first end. The first sub body second inner surface may define a first sub body second bore extending from the first sub body first bore toward the first sub body first end. The first sub body recess wall may extend radially between the first sub body first inner surface and the first sub body second inner surface. The bulkhead body may be in the first sub body second bore. The bulkhead body may include a bulkhead o-ring compressively engaged with an interior surface of the first sub body radially adjacent to the first sub body second bore. A first bulkhead pin and a second bulkhead pin may extend from either end of the bulkhead body. A bulkhead retainer positioned in the first sub body first bore adjacent the first sub body recess wall. The bulkhead retainer may be dimensionally configured to secure the bulkhead body within the first sub body second bore. The second sub body may have a second sub body first end and a second sub body second end opposite the second sub body first end. The second sub body may further include a second sub body first inner surface defining a second sub body first bore extending from the second sub body second end toward the second sub body first end. The first sub body may be rotatably coupled to the second sub body and a portion of the first sub body is positioned within the second sub body first bore.

An exemplary embodiment of a perforating gun assembly may include a first perforating gun housing, a first shaped charge provided within the first perforating gun housing, and an alignment sub coupled to the first perforating gun housing. The alignment sub may include a first sub body and a second sub body rotatably coupled to the first sub body.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a cross-sectional view of an alignment sub according to an embodiment;

FIG. 2 is a perspective view of an alignment sub according to the embodiment shown in FIG. 1;

FIG. 3 is a side elevated view of an alignment sub according to the embodiment shown in FIG. 1;

FIG. 4 is a front elevated view of an alignment sub according to the embodiment shown in FIG. 1;

FIG. 5 is a rear elevated view of an alignment sub according to the embodiment shown in FIG. 1;

FIG. 6 is a front side perspective view of a first sub body part of an alignment sub according to an embodiment;

FIG. 7 is a rear side perspective view of a first sub body part of an alignment sub according to the embodiment shown in FIG. 6;

FIG. 8 is a front side perspective view of a second sub body part of an alignment sub according to an embodiment;

FIG. 9 is a rear side perspective view of a second sub body part of an alignment sub according to the embodiment shown in FIG. 8;

FIG. 10 is a cross-sectional side view of a second sub body part of an alignment sub according to the embodiment shown in FIGS. 8 and 9;

FIG. 11 is a cross-sectional side view of a partially assembled alignment sub according to an embodiment, showing a first sub body part;

FIG. 12 is a cross-section side view of a partially assembled alignment sub according to the embodiment shown in FIG. 11, showing a first sub body part and a second sub body part;

FIG. 13 is a perspective view of an alignment sub according to an embodiment;

FIG. 14 is a side elevated view of an alignment sub according to the embodiment shown in FIG. 13;

FIG. 15 is a front elevated view of an alignment sub according to the embodiment shown in FIG. 13;

FIG. 16 is a rear elevated view of an alignment sub according to the embodiment shown in FIG. 13;

FIG. 17 is a front side perspective view of a first sub body part of an alignment sub according to an embodiment;

FIG. 18 is a rear side perspective view of a first sub body part of an alignment sub according to the embodiment shown in FIG. 17;

FIG. 19 is a front side perspective view of a second sub body part of an alignment sub according to an embodiment;

FIG. 20 is a rear side perspective view of a second sub body part of an alignment sub according to the embodiment shown in FIG. 19;

FIG. 21 is a cross-sectional side view of a second sub body part of an alignment sub according to the embodiment shown in FIGS. 19 and 20;

FIG. 22 is a cross-sectional side view of an orienting tandem seal adapter according to an embodiment;

FIG. 23 is a perspective view of an orienting tandem seal adapter according to the embodiment shown in FIG. 22;

FIG. 24 is a front elevated view of an orienting tandem seal adapter according to the embodiment shown in FIG. 22;

FIGS. 25 and 26 are perspective views of a perforating gun string according to an embodiment, including an orienting tandem seal adapter and alignment sub;

FIG. 27A shows a wellbore tool string positioned inside a wellbore casing according to an embodiment; and

FIG. 27B shows a wellbore tool string positioned inside a wellbore casing according to an embodiment.

Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to emphasize specific features relevant to some embodiments.

The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.

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.

FIGS. 1-10 show an exemplary embodiment of an alignment sub 100. The alignment sub 100 may include a first sub body part 101 and a second sub body part 118 rotatably coupled to the first sub body part 101.

With reference to FIGS. 1-4 and 6-7, the first sub body part 101 is shown in greater detail. The first sub body part 101 in the exemplary embodiment includes a first sub body part first end 102 and a first sub body part second end 103 spaced apart from the first sub body part first end 102. The first sub body part 101 includes an insertable portion 104 axially adjacent the first sub body part first end 102. A first sub body part bore 105 may extend in an x-direction along a central axis of rotation X (see FIG. 1) through a first sub body part insertable portion 104, between the first sub body part first end 102 and the first sub body part second end 103. According to an aspect, the first sub body part bore 105 has a bore longitudinal axis that is the central axis of rotation X of the alignment sub 100. In the exemplary embodiment shown in FIGS. 1-2, for example, a first sub body part recess 111 may extend from the first sub body part second end 103 to the first sub body part bore 105. The first sub body part bore 105 is defined on a first end by the first sub body part first end 102, and on a second end by a first sub body part recess wall 112. The first sub body part recess wall 112 extends radially between the first sub body part recess 111 and the first sub body part bore 105.

The first sub body part bore 105 may be dimensionally configured to receive an electrical assembly 136 for providing electrical conductivity through the length of the alignment sub 100. According to an aspect, the electrical assembly 136 is positioned in the first sub body part bore 105. The electrical assembly 136 may be, for example and not limitation, an electrically contactable bulkhead assembly including a bulkhead body 137 that is sealingly secured in the first sub body part bore 105. According to an aspect, the bulkhead body 137 may include a sealing element, such as a bulkhead o-ring (not labeled), for frictionally and compressively engaging with an interior surface 177 of the first sub body part 101 radially adjacent to the first sub body part bore 105. The frictional engagement pressure seals the bulkhead body 137 in the first sub body part bore 105.

The electrical assembly 136, e.g., the bulkhead assembly 137, may include a bulkhead first end 138 including a first end bulkhead pin 139, and a bulkhead second end 140 including a second end bulkhead pin 141. The first end bulkhead pin 139 may be in electrical connection with the second end bulkhead pin 141. Each of the first end bulkhead pin 139 and second end bulkhead pin 141 are electrically contactable components. When used in a wellbore tool string to align a first wellbore tool 201 with a second wellbore tool 202 (see, e.g., FIG. 25), the first sub body part 101 may be non-rotatably coupled to a first wellbore tool 201, the second sub body part 118 may be non-rotatably coupled to a second wellbore tool 202, and the second sub body part 118 may be rotatably coupled to the first sub body part 101. The electrical assembly 136 positioned in the alignment sub 100 provides electrical conductivity through the alignment sub 100 from the first wellbore tool 201 to the second wellbore tool 202. The electrical assembly 136 provides electrical communication along a wellbore tool string when the first end bulkhead pin 139 is in contact with an electrically contactable component in a wellbore tool coupled to the second sub body part first end 119, and when the second end bulkhead pin 141 is in contact with an electrically contactable component in a wellbore tool coupled to the first sub body part second end 103.

A bulkhead retainer nut 142 is positioned in the first sub body part recess 111 to secure the bulkhead assembly 137 in position in the first sub part bore 105. The bulkhead retainer nut 142 is positioned in the first sub body part recess 111 adjacent each of the first sub body part recess wall 112 and the first sub body part bore 105, and is dimensionally configured to contact an interior surface of the first sub body part 101 radially adjacent to the first sub body part recess 111. In the exemplary embodiment as shown in FIG. 1, the first sub body part 101 includes a threaded surface interior portion 113 that receives a threaded side surface 143 of the bulkhead retainer nut 142 in a threaded engagement so that the bulkhead retainer nut 142 is threadedly secured to the first sub body part 101. A bulkhead retainer nut aperture 144 is formed through the bulkhead retainer nut 142 such that the second end bulkhead pin 141 extends through the bulkhead retainer nut aperture 144. According to an aspect, the first sub body part recess 111 may be dimensionally configured to receive and house an end of an adjacent wellbore tool component, such as, for example and not limitation, an end of a shaped charge positioning device housed in a first wellbore tool 201 (see, e.g., FIG. 26). The second end bulkhead pin 141 of the bulkhead assembly 137 extends into the first sub body part recess 111. In the embodiment shown in FIG. 26, the first wellbore tool 201 is coupled to the first sub body part second end 103, such that an electrically contactable portion of the first wellbore tool 201 is in electrical contact with the second end bulkhead pin 141.

With continued reference to FIGS. 1-3 and 6-7, the first sub body part 101 in the exemplary embodiment includes on its first end 102 a first sub body part shoulder 106 formed adjacent the first end of the first sub body part bore 105. A first sub body part aperture 107 may be formed in the first sub body part shoulder 106, which may extend from the first sub body part bore 105 through the first sub body part shoulder 106. The first sub body part aperture 107 may have a diameter that is smaller than a diameter of the bulkhead body 137, so as to prevent the bulkhead body 137 from passing through the first sub body part bore 105. According to an aspect, the first sub body part aperture 107 is formed in the first sub body part shoulder 106 in alignment with the bulkhead first end 138, and the first end bulkhead pin 139 has a diameter that is less than the diameter of the first sub body part aperture 107 such that the first end bulkhead pin 139 extends through the first sub body part aperture 107 and into an interior of the second sub body part 118. According to an aspect, each of the bulkhead first end 138 and the first end bulkhead pin 139 may extend through the first sub body part aperture 107.

The second sub body part 118 in an exemplary embodiment is shown in FIGS. 1 and 8-10. The second sub body part 118 may include a second sub body part first end 119 and a second sub body part second end 120 spaced apart from the second sub body part first end 119. A second sub body part cavity 121 extends axially from the second sub body part second end 120 toward the second sub body part first end 119. According to an aspect, the second sub body part cavity 121 has a cavity longitudinal axis that is a central axis of rotation X of the alignment sub 100, such that the first sub body part bore 105 and the second sub body part cavity 121 are axially aligned. According to an aspect, a portion of the first sub body 101 is positioned within the second sub body part cavity 121.

In the exemplary embodiment, the second sub body part 118 may include a second sub body part medial channel 123 provided axially adjacent the second sub body part cavity 121 and away from the second sub body part second end 120. A second sub body part cavity wall 122 positioned away from the second sub body part second end 120 and extending inward in the second sub body part cavity 121 may separate the second sub body part cavity 121 from the second sub body part medial channel 123, such that the second sub body part cavity 121 has a first diameter D1, and the second sub body part medial channel 123 has a second diameter D2. According to an aspect, the first diameter D1 of the second sub body part cavity 121 is greater than the second diameter D2 of the second sub body part medial channel 123. The second sub body part 118 in an exemplary embodiment includes a second sub body part recess 124 formed adjacent the sub body part medial channel 123, extending in a x-direction from the second sub body part first end 119 toward the second sub body part second end 120 and the second sub body part cavity 121. The second sub body part recess 124 is separated from the second sub body part medial channel 123 by a second sub body part recess wall 125. According to an aspect, the diameter of the second sub body part recess 124 is greater than the second diameter D2 of the second sub body part medial channel 123. The second wellbore tool 202 is coupled to the second sub body part first end 119, such that an electrically contactable portion of the second wellbore tool 202 is in electrical contact with the first end bulkhead pin 139 (see FIG. 26).

In the exemplary embodiment, a second sub body part retainer ring 130 retains the first sub body part 101 inside the second sub body part 118. The second sub body part retainer ring 130 is engaged with an inner surface of the second sub body part 118 and with the first sub body part 101 to retain the position of the first sub body part 101 inside the second sub body part 118. The second sub body part retainer ring 130 extends from the second sub body part first end 119 to the second sub body part recess wall 125, and may include a retainer ring shoulder 134 that abuts the first sub body part first end 102. According to an aspect, the second sub body part retainer ring 130 is dimensionally configured to secure the first sub body part insertable portion 104 to the second sub body part 118. In the embodiment shown in FIGS. 1-10, the second sub body part retainer ring 130 includes a contoured inner wall 135 extending from the second sub body part first end 119 to the retainer ring shoulder 134. In a further embodiment, as shown in FIGS. 11-21, the second sub body part retainer ring shoulder 134 and the first sub body part first end 102 are abutting. According to an aspect, the first sub body part insertable portion 104 includes a threaded surface portion 110 positioned in the second sub body part recess 124.

The second sub body part retainer ring 130 includes a threaded collar 133 extending from the second sub body retainer ring shoulder 134 toward the second sub body part recess wall 125, wherein the threaded collar 133 is threadedly engaged with the threaded surface portion 110 to threadedly secure the first sub body part 101 in the second sub body part 118. With reference to FIGS. 1, 5, 12, and 16, a socket screw 131 is positioned in a second sub body part retainer ring screw socket 132 formed in the second sub body part retainer ring 130. According to an aspect, the second sub body part retainer ring screw socket 132 may rotationally fix the retainer ring 130 to the first sub body part 101. The retainer ring screw socket 132 in the exemplary embodiment at least partially abuts one of the first sub body part first end 102 and the first sub body part insertable portion 104.

A locking mechanism, such as a sub locking screw 129, in the alignment sub 100 is used to fix the relative angular/rotational position of the first sub body part 101 relative to an angular/rotational position of the second sub body part 118. According to an aspect, more than one sub locking screw 129 may be used to lock the position of the first sub body part 101 relative to the position of the second sub body part 118. According to an aspect, the sub locking screw 129 may be switchable between an unlocked state and a locked state such that, when the sub locking screw 129 is in the locked state, the angular position of the first sub body part 101 is fixed relative to an angular position of the second sub body part 118, and when the sub locking screw 129 is in the unlocked state, the second sub body part 118 is able to rotate relative to the first sub body part 101.

According to an aspect, the sub locking screw 129 is dimensionally configured to be secured in a locking screw socket 128 formed in a second sub body part rib 147. In the exemplary embodiment shown in FIG. 1, the second sub body part second end 120 is defined by a second sub body part rib 147 projecting from an outer surface of the second sub body part 118 and a sub locking screw socket 128 is formed in and extends through the second sub body part rib 147. The second sub body part second end 120/second sub body part rib 147 are positioned around a sub locking screw channel 114 formed in the first sub body part 101. The sub locking screw channel 114 in the exemplary embodiment overlaps with the sub locking screw socket 128 in an axial direction. In an unlocked state, the first sub body part 101 is able to rotate within the second sub body part cavity 121. In a locked state, the sub locking screw 129 is secured in the sub locking screw socket 128, such that an end of the sub locking screw 129 is secured in the sub locking screw channel. According to an aspect, the alignment sub 100 may include a plurality of locking screw sockets 128 spaced equidistantly about the second sub body part rib 147.

In the exemplary embodiment, the locking screw channel 114 includes a channel lip 115 that is formed on the first sub body part 101 axially adjacent to the locking screw channel 114. The channel lip 115 defines a boundary of the locking screw channel 114 in which the sub locking screw 129 is received and secured when the alignment sub 100 is in the locked state. According to an aspect, a diameter of the first sub body part 101 at the channel lip 115 is larger than a diameter of the first sub body part 101 at the locking screw channel 114. In the exemplary embodiment, the channel lip 115 extends outward from the first sub body part 101 and abuts the second sub body part cavity wall 122 to align the locking screw channel 114 with the sub locking screw socket 128 in the second sub body part rib 147 for locking the alignment sub 100 in the locked state.

The first sub body part 101 according to the exemplary embodiment is secured in the second sub body part cavity 121 and the second sub body part medial channel 123. According to an aspect, the first sub body part 101 includes an interior o-ring 109 positioned in an interior o-ring channel 108 extending around the first sub body part 101 at an axial position between the channel lip 115 and the sub body part first end 102, wherein the one o-ring 109 contacts and frictionally engages a surface of the second sub body part medial channel 123. The first sub body part 101 may also include a first sub body part rib 146 formed adjacent the locking screw channel 114, such that the first sub body part rib 146 abuts the second sub body part rib 147. The first sub body part rib 146 and second sub body part rib 147 together form a central alignment sub rib 145, and a placement tool hole 175 may be formed in each of the first sub body part rib 146 and the second sub body part rib 147 for positioning of the alignment sub 100 when coupled to adjacent wellbore tools as part of the wellbore tool string. According to an aspect, the placement tool holes 175 may be dimensioned and positioned on the first sub body part rib 146 and the second sub body part rib 147 as required by the particular application. The placement tool holes may be circular in shape, as shown in the embodiment of FIGS. 11-21. Alternatively, some or all of the placement tool holes 175 may be shaped in a horseshoe or arc-shaped configuration as shown in the embodiment of FIGS. 1-10.

In an exemplary embodiment, each of the first sub body part 101 and the second sub body part 118 include external threading for coupling to an adjacent wellbore tool to form a wellbore tool string. The first sub body part 101 includes a threaded exterior portion 116 that is dimensionally configured to couple to a first perforating gun housing of a first wellbore tool 201 (see FIG. 26). The second sub body part 118 includes a second sub body part threaded exterior portion 127 that is dimensionally configured to couple to a second perforating gun housing of a second wellbore tool 202.

In the exemplary embodiment, the first sub body part 101 includes a first sub body part external o-ring channel 117 having a first sub body part external o-ring 148 positioned therein, wherein the first sub body part external o-ring channel 117 is formed between the first sub body part rib 146 and the first sub body part threaded exterior portion 116. The second sub body part 118 may include a second sub body part external o-ring channel 126 having a second sub body part external o-ring 149 positioned therein, wherein the second sub body part external o-ring channel 126 is formed between the second sub body part rib 147 and the second sub body part threaded exterior portion 127.

With reference to FIGS. 22-26, a tandem seal adapter (TSA) 150 may be used in conjunction with one or more alignment subs 100, 100′ in a wellbore tool string 200 to align adjacent wellbore tools 201, 202 and to provide orientation of the wellbore tool string 200 while in a wellbore. In an exemplary embodiment and as shown in FIG. 22, the TSA 150 includes an adapter body 151. The adapter body 151 may be a solid cylindrical body including a first end 152, a second end 156 spaced apart from the first end 152, and an adapter bore 160 extending axially through the adapter body 151. A first adapter body recess 154 defined by a first adapter body recess wall 155 extends inwardly from the first end 152, and a second adapter body recess 158 defined by a second adapter body recess wall 159 extends inwardly from the second end 156. The first adapter body recess 154 may have an inner threaded surface 153 for threaded engagement with an adjacent wellbore tool or sub, and the second adapter body recess 158 may have an inner threaded surface 157 for threaded engagement with an adjacent wellbore tool or sub. The adapter bore 160 extends from the first adapter body recess wall 155 to the second adapter body recess wall 159.

A feedthrough rod/contact rod 162 is positioned in the axial bore 160 of the adapter body 151. When the contact rod 162 is positioned in the bore 160, it is held in position by a retainer nut 165. Each of the contact rod 162 and the retainer nut 165 is formed from an electrically conductive material. With continued reference to FIG. 22, a contact rod first end 163 is positioned adjacent the first adapter body recess 154, and a contact rod second end 164 is positioned adjacent the second adapter body recess 158. In the exemplary embodiment shown in FIG. 24, the retainer nut 165 includes a retainer nut recession dimensionally configured to receive a bulkhead pin (e.g., a first end bulkhead pin 139 or a second end bulkhead pin 141 of the alignment sub 100) from an adjacent wellbore tool or an adjacent alignment sub 100. The contact rod second end 164 may include a contact rod recession 166 dimensionally configured to receive a bulkhead pin from an adjacent wellbore tool.

The contact rod 162 is electrically isolated from electrical contact with the adapter body 151 by a non-conductive 3-piece insulator 167 that extends around the contact rod between the contact rod first end 163 and the contact rod second end 164. The insulator/insulating jacket 167 in the exemplary embodiment includes a first end piece 168 positioned around the contact rod first end 163, a second end piece 169 positioned around the contact rod second end 164, and a medial piece 170 extending between the contact rod first end 163 and the contact rod second end 164.

In an embodiment and with reference to FIGS. 27A and 27B, two or more fins 171 are secured to an outer surface of the adapter body 151 to space the wellbore tool string 200 apart from a surface of a wellbore casing and to assist in orienting the tool-string and thereby the direction of the perforations in a specific desired direction. The fins 171 orient the wellbore tool string 200 in the wellbore so that when the wellbore tool string 200 is laying horizontally in a wellbore casing 203, the wellbore tool string 200 is spaced apart from a horizontal surface 204 of the wellbore casing 203 by the fins 171 so that the tool string 200 and the shaped charges housed in the tool string 200 are oriented in a desired direction. The fins 171 adjust the axial positioning of the wellbore tool string 200 in the wellbore by moving the wellbore tool string 200 away from the horizontal surface 204 of the wellbore casing 203. According to an aspect, the fins 171 space apart the wellbore tool string 200 from the wellbore casing 203 such that an unwanted or unintentional rotation or rolling of the tool-string 200 downhole is prevented so that the perforations are always oriented or aligned in a desired specific direction within certain degrees of accuracy. The accuracy or degree of limitation which the fins can hold the tool string 200 in the desired location depends on the overall tool string 200 design, as well as the height H of the fins 171 compared to the inner-diameter ID of the wellbore casing 203.

In the exemplary embodiment, the two or more fins 171 are positioned on the outer surface of the TSA 150 on a top side of the TSA 150. The two or more fins 171 may be positioned generally in alignment with the firing path of the shaped charges housed in the housings 201, 202 of the wellbore tool string 200. In an embodiment, the firing path of the shaped charges may be aligned with a top side of the perforating gun housing and the TSA, such that the pitch of the firing path is 0 degrees. Alternatively, the firing path of the shaped charges may be aligned with a bottom side of the perforating gun housing, such that the pitch of the firing path is 180 degrees. In such an embodiment, the two or more fins 171 are positioned generally about 180 degrees from the firing path of the shaped charges, such that the two or more fins 171 maintain an orientation of the wellbore tool string 200 for firing the shaped charges in a downward direction. According to an aspect, fin screw holes 173 may be formed in the adapter body 151 extending from the outer surface of the adapter body 151 toward the center of the adapter body 151 for receiving a screw 172 that passes through the fin 171 for attachment of the fin 171 to the adapter body 151. In the exemplary embodiment, three fins are included in the TSA 150. However, any number of fins 171 in accordance with this disclosure may be used to provide the desired axial positioning of the wellbore tool string in the wellbore casing. In an embodiment, the fins 171 may be spaced apart from one another about the adapter body 151. For example, the fins 171 may be mounted at a distance of about 60 degrees from one another. In an embodiment, the TSA 150 may include a circumferential recess 174 formed around the exterior surface of the adapter body 151. According to an aspect, the circumferential recess 174 may receive a support structure, for example a lifting plate, make-up plate, or rig-up plate, for use in lifting up the tool string 200 for vertical assembly of the tool string components (e.g., gun housing 201, gun housing 202, TSA 150, and/or alignment sub 100).

The wellbore tool string 200, such as a perforating gun string, may include an orienting alignment sub assembly, which includes each of the alignment sub 100 and the TSA 150 as described above and shown in FIGS. 25-26. The first perforating gun housing 201 houses a shaped charge holder with an electrically contactable component, and includes a threaded end. The first sub body part 101 of the alignment sub 100 includes a first sub body part first end, a first sub body part insertable portion 104 axially adjacent to the first sub body part first end, and a first sub body part bore 105 extending from the first sub body part first end 102 in a x-direction through the first sub body part insertable portion 104. An electrical component 136 (e.g., an electrically contactable bulkhead assembly 137) is positioned in the first sub body part bore 105.

A second sub body part 118 is positioned around and rotatably engaged with the first sub body part insertable portion 104. The second sub body part 118 includes a second sub body part recess 124 extending in a x-direction from a second sub body part first end 119 toward a second sub body part second end 120, a second sub body part cavity 121 extending in a x-direction from the second sub body part second end 120 toward the second sub body part first end 119, and a second sub body part medial channel 123 extending from the second sub body part recess 124 to the second sub body part cavity 121, wherein the first sub body part insertable portion 104 is positioned in the second sub body part cavity 121 and the second sub body part medial channel 123.

A tandem sub assembly 150 is connected to the second sub body part 118, and includes an adapter body 151 having a first adapter body recess 154 extending in a x-direction from a first adapter body end 152, wherein the first adapter body recess 154 is defined by a first adapter body recess wall 155, a second adapter body recess 158 extending in a x-direction from a second adapter body end 156, wherein the second adapter body recess 158 is defined by a second adapter body recess wall 159, and an adapter bore 160 extending in a x-direction from the first adapter body recess wall 155 to the second adapter body recess wall 159. A contact rod 162 is positioned in the adapter bore 160 and is electrically connected to the electrical assembly 136. The tandem sub assembly 150 includes a plurality of fins 171 positioned externally on the adapter body 151.

A second alignment sub 100′ as described above is coupled to the tandem sub assembly 150, and includes a second electrical assembly 136 that is electrically connected to the contact rod 162. A second perforating gun housing 202 housing a shaped charge holder with an electrically contactable component that is electrically connected to the second electrical assembly 136′ has a threaded end that is coupled to the second alignment sub 100′.

According to an aspect, the first gun housing 201 includes surface scallops 203, and the second gun housing 202 includes surface scallops 204, wherein the first gun housing surface scallops 203 and the second gun housing surface scallops 204 align with a firing path of an internal shaped charge. Rotation of the first sub body part 101 in the second sub body part 118 aligns the first gun housing surface scallops 203 with the second gun housing surface scallops 204. When the first gun housing surface scallops 203 are aligned with the second gun housing surface scallops 204, the alignment sub 100 may be locked as described above with a lock screw to fix the angular position of the first gun housing 201 relative to the second gun housing 202.

The two or more fins 171 orient the rotational position of the perforating gun string 200 in a wellbore. According to an aspect, the two or more fins 171 are positioned on the adapter body 151 in a spaced apart configuration. In the exemplary embodiment, each of the two or more fins 171 are radially offset from the surface scallops 203, 204 when the gun housing 201, 202 are aligned, such that the fins 171 are offset from the shaped charge firing path by about 30 degrees.

Embodiments of the disclosure are further associated with a method of aligning a pitch of shaped charges in a wellbore tool string. A first wellbore tool 201 is coupled to a first end 119 of an alignment sub 100 comprising a first sub body part 101 rotatably coupled to a second sub body part 118. According to an aspect, the first sub body part 101 is rotatably coupled to the second sub body part 118 by inserting an insertable portion 104 of the first sub body part 101 into a cavity 121 of the second sub body part 118. A second wellbore tool 202 is coupled to a second end 102 of the alignment sub 100. According to an aspect, the first wellbore tool 201 is coupled to the alignment sub first end 119 by threadedly coupling, and the second wellbore tool 202 is coupled to the alignment sub second end 102 by threadedly coupling.

The first wellbore tool 201 is rotated relative to the second wellbore tool 202 to align a wellbore housing scallop 203 on the first wellbore tool 201 with a wellbore housing scallop 204 on the second wellbore tool 202. The alignment sub 100 is locked to retain the alignment of the first wellbore housing scallop 203 relative to the second wellbore housing scallop 204. According to an aspect, locking the alignment sub 100 may include at least one of inserting a sub locking screw 129 through the second sub body part 118 into the second sub body part cavity 121 to contact the first sub body part insertable portion 104, and inserting a second sub body part retainer ring 130 into the recess 124 of the second sub body part to secure the first sub body part insertable portion 104 to the second sub body part recess 124 and to retain the first sub body part first end 102 within the second sub body part recess 124.

This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.

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 the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.

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.

This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single 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 this disclosure.

Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.

Claims

1. An alignment sub, comprising: a first sub body having a first sub body first end and a first sub body second end opposite the first sub body first end, the first sub body comprising: a first sub body first inner surface defining a first sub body first bore extending from the first sub body second end towards the first sub body first end;a first sub body second inner surface defining a first sub body second bore extending from the first sub body first bore toward the first sub body first end, the first sub body second bore having a smaller diameter than the first sub body first bore; anda first sub body recess wall extending radially between the first sub body first inner surface and the first sub body second inner surface;a bulkhead body provided in the first sub body second bore;bulkhead retainer dimensionally configured to secure the bulkhead body within the first sub body second bore, the bulkhead retainer being positioned within the first sub body first bore adjacent the first sub body recess wall; anda second sub body having a second sub body first end and a second sub body second end opposite the second sub body first end, the second sub body comprising: a second sub body first inner surface defining a second sub body first bore; anda sub locking screw switchable between an unlocked state and a locked state such that, when the sub locking screw is in the locked state, a rotational position of the first sub body is fixed relative to a rotational position of the second sub body;wherein the first sub body is rotatably coupled to the second sub body and a portion of the first sub body is positioned within the second sub body first bore,the first sub body further comprises a channel provided on the outer surface of the first sub body;the second sub body further comprises a socket extending through the second sub body at a position radially overlapping with the channel;the sub locking screw is secured in the socket;the outer surface of the first sub body includes a channel lip axially adjacent to the channel; andan outer diameter of the first sub body at the channel lip is greater than an outer diameter of the first sub body at the channel.

2. The alignment sub of claim 1, wherein: the second sub body first bore extends from the second sub body second end toward the second body first end, andthe second sub body further comprises:a second sub body second inner surface defining a second sub body second bore axially displaced from the second sub body first bore toward the second sub body first end,wherein the first sub body first end is positioned in the second sub body second bore.

3. The alignment sub of claim 1, wherein the first sub body further comprises: a first sub body third inner surface defining a first sub body third bore extending from the first sub body second bore to the first sub body first end, wherein the first sub body third bore is dimensionally configured to receive a first bulkhead pin of the bulkhead body.

4. The alignment sub of claim 1, further comprising: a first bulkhead pin extending from a first end of the bulkhead body, anda second bulkhead pin extending from a second end of the bulkhead body, wherein:the bulkhead body includes a bulkhead o-ring compressively engaged with the first sub body second inner surface radially adjacent to the first sub body second bore;the bulkhead retainer further comprises a bulkhead retainer aperture and an outer surface in threaded engagement with the first sub body first inner surface; andthe second bulkhead pin extends through the bulkhead retainer aperture.

5. The alignment sub of claim 1, wherein a longitudinal axis of the bulkhead body is a central axis of rotation of the second sub body around the first sub body.

6. A perforating gun assembly comprising: a first perforating gun housing;a first shaped charge provided within the first perforating gun housing;an alignment sub coupled to the first perforating gun housing, the alignment sub comprising: a first sub body; anda second sub body rotatably coupled to the first sub body via a non-threaded interface between an outer surface of the first sub body and an inner surface of the second sub body; anda sub locking screw switchable between an unlocked state and a locked state such that, when the sub locking screw is in the locked state, a rotational position of the first sub body is fixed relative to a rotational position of the second sub body;wherein the first sub body further comprises a channel provided on the outer surface of the first sub body;the second sub body further comprises a socket extending through the second sub body at a position radially overlapping with the channel;the sub locking screw is secured in the socket;the outer surface of the first sub body includes a channel lip axially adjacent to the channel; andan outer diameter of the first sub body at the channel lip is greater than an outer diameter of the first sub body at the channel.

7. The perforating gun assembly of claim 6, wherein: in the unlocked state, the sub locking screw is radially spaced apart from the outer surface of the first sub body radially adjacent the channel; andin the locked state, the sub locking screw is in frictional contact with the outer surface of the first sub body radially adjacent the channel.

8. The perforating gun assembly of claim 6, wherein the socket is one of a plurality of sockets spaced apart about the second sub body.

9. The perforating gun assembly of claim 6, wherein the second sub body comprises: a second sub body first end; anda second sub body second end spaced apart from the second sub body first end, the inner surface of the second sub body defining a second sub body first bore extending from the second sub body second end toward the second sub body first end,wherein the first sub body has a first sub body first end positioned in the second sub body first bore.

10. The perforating gun assembly of claim 9, further comprising: a second sub body retainer ring provided in the second sub body first bore,wherein the second sub body retainer ring is engaged with each of the inner surface of the second sub body and the first sub body to prevent axial movement of the first sub body relative to the second sub body.

11. The perforating gun assembly of claim 10, wherein: the first sub body first end further comprises a threaded surface portion; andthe second sub body retainer ring is threadedly engaged with the first sub body threaded surface portion.

12. The perforating gun assembly of claim 6, wherein the first sub body comprises: a first sub body first inner surface defining a first sub body first bore extending between a first sub body first end and a first sub body second end, wherein a longitudinal axis of the first sub body bore is a central axis of rotation of the alignment sub.

13. The perforating gun assembly of claim 6, wherein: the first sub body includes a first sub body threaded exterior portion that is coupled to the first perforating gun housing.

14. The perforating gun assembly of claim 13, further comprising: a second perforating gun housing; anda second shaped charge provided within the second perforating gun housing;wherein the second sub body is coupled to the second perforating gun housing.

15. The perforating gun assembly of claim 14, wherein the second sub body includes a second sub body threaded exterior portion coupled to the second perforating gun housing.

16. The perforating gun assembly of claim 6, further comprising: a second sub body retainer ring provided in the second sub body,wherein the second sub body comprises: a second sub body first end; anda second sub body second end spaced apart from the second sub body first end, the inner surface of the second sub body defining a second sub body first bore extending from the second sub body second end toward the second sub body first end, the first sub body first end is positioned in the second sub body, and the second sub body retainer ring is engaged with each of the inner surface of the second sub body and with the first sub body to prevent axial movement of the first sub body relative to the second sub body.

17. The perforating gun assembly of claim 6, wherein: the first sub body comprises: a first sub body first inner surface defining a first sub body first bore extending from a first sub body second end towards a first sub body first end;a first sub body second inner surface defining a first sub body second bore extending from the first sub body first bore toward the first sub body first end; anda first sub body recess wall extending radially between the first sub body first inner surface and the first sub body second inner surface; andthe second sub body comprises:a second sub body first inner surface defining a second sub body first bore extending from a second sub body second end toward a second sub body first end.

18. The perforating gun assembly of claim 17, further comprising: a bulkhead body provided in the first sub body second bore, wherein the bulkhead body includes a bulkhead o-ring compressively engaged with the first sub body second inner surface radially adjacent to the first sub body second bore; anda first bulkhead pin and a second bulkhead pin extending from either end of the bulkhead body.

19. The perforating gun assembly of claim 18, further comprising: a bulkhead retainer positioned in the first sub body first bore adjacent the first sub body recess wall, wherein the bulkhead retainer is dimensionally configured to secure the bulkhead body within the first sub body second bore, the bulkhead retainer having an outer surface in threaded engagement with the first sub body first inner surface and defining a central aperture through which the first bulkhead pin extends.