The present application is a non-provisional application of provisional U.S. Patent Application No. 63/434,421 filed Dec. 21, 2022, the entire disclosure of which is incorporated herein by reference.
Wells are often drilled to extract hydrocarbons, such as oil and gas. After drilling a wellbore that traverses a hydrocarbon-bearing formation, a casing string is installed to reinforce portions of the wellbore. A casing string comprises large diameter metal tubulars that are connected end-to-end, lowered into the wellbore, and cemented in place. The casing string increases the integrity of the wellbore and provides a structure for supporting other wellbore equipment such as production tubing used for producing fluids from one or production zones of the formation to surface. When a production zone is lined with casing, the casing is perforated to allow the formation fluids to enter the wellbore. These perforations are hydraulic openings that extend through the casing and into the surrounding formation.
Typically, perforations are created by lowering a perforating gun string downhole and detonating a series of explosive shaped charges adjacent to the production zone. For safety, perforating guns may be transported to a wellsite in a partially unassembled state to prevent accidental detonation. Once fully assembled at the wellsite, a perforating gun string may be lowered into the cased wellbore on an appropriate conveyance, such as a wireline. An explosive train is then initiated to detonate the shaped charges in a predetermined, serial fashion. The perforating gun string may then be retrieved to the surface. Common problems associated with these perforating gun strings may include, for example, occasional detonation failure after lowering the perforating gun string to its target depth.
These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.
The disclosure is directed to a perforating tool assembly used during perforation of wellbore casings for hydrocarbon recovery, and more particularly, this disclosure relates to an electrical contact of the perforating tool assembly. The present disclosure may address reliability issues. Specifically, the features disclosed herein may address the problem of occasional detonation failure.
Servicing rig 108 may be a drilling rig, completion rig, workover rig, or other mast structure supporting work string 104. In some examples, servicing rig 108 comprises a derrick and rig floor through which work string 104 extends downwards into wellbore 110. As will be shown in
As illustrated, work string 104 may comprise a conveyance 106 and a perforating tool assembly 102, i.e., “perforating gun string,” “gun string,” or “gun assembly,” comprising one or more perforating guns. In addition, work string 104 may comprise other downhole tools, such as one or more packers, one or more completion components, e.g., screens and/or production valves, one or more sensing components and/or measuring equipment, i.e., downhole sensors, and other equipment not shown in
As will be shown in later figures, e.g.,
As illustrated, a wellbore 214 may extend into a subterranean formation 224 beneath a sea floor 220. A semi-submersible platform 206 is centered over a hydrocarbon-bearing formation 224 located beneath a sea floor 220. A subsea conduit 212 extends from deck 208 of platform 206 to wellhead installation 228 which may include one or more subsea blow-out preventers 230. Platform 206 has a hoisting apparatus 204 and a derrick 202 for raising and lowering tubular strings such as work string 210.
A wellbore 214 extends through various earth strata including subterranean formation 224. Casing 226 is cemented within wellbore 214 by cement 216, as with
The charge tube 312 has a generally continuous tubular construction in this example. However, all other suitable charge tube configurations are also within the scope of this disclosure, such as modular charge tubes formed by snapping together or otherwise interconnecting any number of charge tube segments that each hold one or more perforating charges within a perforating gun. The charge comprises a plurality of charge casings positioned at different positions and firing orientations along the charge tube 312, for example, within the wedged cut-out sections 314. The wedged cut-out sections 314 of the charge tube 312 provide space for charge casings which hold perforating charges (e.g., shaped charges) and metal liners.
A detonator housing 320 according to this disclosure is coupled to the charge tube 312 at one end. The detonator housing 320 includes various features facilitating assembly including for securing a detonator, detonating cord, and other components, as further discussed below, and illustrated in subsequent figures. One purpose of the detonator housing 320 is to safely house the detonator such that it is protected from external influences (e.g., wellbore 110 of
The end alignment 390 is also coupled to the charge tube 312 at the other end opposite the detonator housing. The end alignment aligns the charge tube 312 within the gun body 316. As will be shown in subsequent figures, one or more (e.g., three, four, five, or more) radial protrusions (e.g., ears 610a, 610b, 610c of
The bulkhead 305 provides stability and structure to the perforating gun 310 as well as an interface to connect to a neighboring perforating gun. The bulkhead 305 generally comprises a body, an electrical feedthrough to house one or more electrical connections, and a receptacle to hold a contact pin (e.g., contact pin of
The gun body 316 is the outer tubular body of the perforating gun 310 which houses all the main components of the perforating gun 310 including the charge tube 312, detonator housing 320, end alignment 390, and at least a portion of the bulkhead 305.
Use in the manner described herein may remove or reduce the need for external fasteners, which further increases productivity at the work site by making it easier for an assembler to assemble the perforating gun 310 and/or tubular gun string. For example, one or more sections of (e.g., the end alignment 390, bulkhead 305, detonator housing 320, charge tube 312, gun body 316, or any tubular components of) the perforating gun 310 may, in some examples, be free or essentially free of external fasteners.
As used herein, a “shipping assembly” comprises an at least partially assembled perforating gun which includes at least a gun body 316, a charge tube 312, and end alignment 390, and a bulkhead 305. A shipping assembly would generally not comprise more than a single bulkhead 305, as coupling of multiple perforating guns (e.g., 310a, 310b of
In one or more examples, a detonation signal is transmitted during operation along the perforating tool assembly 102 in a down-going fashion. For example, the detonation signal may proceed from gun to gun, arriving first at the detonator 360a before passing through an electrical feedthrough (e.g., electrical feedthrough 306 of
As mentioned, at least a portion of detonator housing 320a corresponding to the first perforating gun 310a may be disposed within a bulkhead 305b corresponding to the second perforating gun 310b. Coupling of a first perforating gun 310a to a second perforating gun 310b in this manner allows for reliable transmission of a detonation signal (e.g., from an initial firing signal) to propagate along one or more signal conductors (e.g., wires 346a, 346b in
As illustrated, the electrical contact 380 generally comprises an electrical connector 414 and a wire connector 416. The electrical connector 414 and wire connector 416 may comprise two separate pieces or may unitarily form a single piece. For ease of manufacturing, however, it may be desirable for the electrical contact 380 to comprise two separate pieces, which are joined together at a mated connection 432. Alternatively, the two separate pieces may be welded, soldered, crimped, or joined in any suitable manner such that electrical connector 414 and wire connector 416 have a reliable electrical connection.
An example configuration of the electrical connector 414 is that it comprises a contact plate 418 on the upper end, i.e., uphole end, followed by multiple bends 422 leading to another support plate 420 on the lower end with exterior fins 430 that provide stability to that part as well as retention when installed after a wire connector 416 of the electrical contact 380 that accepts the mating end 434. The support plate 420 may also have multiple bends which may aid in the ability to maintain axial contact with the end of the contact pin while providing sufficient spring force to counteract deformation caused by the pin. The support plate 420 also may comprise fins 430 which may further provide centralization, retention, and stability as an anchor point. Specifically, an inner diameter of the end alignment 390 (e.g., referring to
An example configuration of the mated connection 432 (e.g., wire connector) is that it comprises one or more mating slots 436 and a stop 438. In this way, the mating end 434 of the electrical connector 414 may be inserted into the one or more mating slots 436 until it reaches the stop 438. In some examples, the mated connection 432 may comprise or be accompanied by one or more crimped connections, such as by crimping the one or more mating slots 436 on the mating end 434 of the electrical connector 414. Use in this manner may ensure a good, reliable connection between a wire 346 and the electrical contact 380, and therefore by extension, between a first perforating gun 310a and a second perforating gun 310b of a gun string (e.g., referring to
One or more crimped connections may additionally be used to electrically couple wire 346 to the wire connector 416. As illustrated, the wire connector may, in some examples, comprise two wire crimping sections 440, 442. As illustrated, the two wire crimping sections 440 and 442 may be vertically displaced from each other relative to a longitudinal axis of the mating end 434 of the electrical connector 414. Use in this manner may, in some examples, allow for more secure fastening of the wire 346 to the wire connector 416.
As illustrated, the protrusion 450 of the mating end 434 of the electrical connector 414 may seat against the stop 438 of the wire connector 416. This particular arrangement may, in some examples, ensure that the mating end 523 is inserted at the correct insertion distance in the mating slot(s) 436 (e.g., referring to
The contact pin 502 may be held in place by any suitable mechanism. For example, retaining nut(s) 504 are shown that serve to ensure that the contact pin is centralized within the electrical feedthrough 306 of the bulkhead 305. As illustrated, contact pin 502 extends from a receptable 560 formed in the first end of the bulkhead 305 through the electrical feedthrough 306 and to a second end of the bulkhead 305 into the end alignment 390. The receptable 560 of the bulkhead 305 may be threaded. The contact pin 502 may comprise, for example, a sliding mandrel 508 and a spring 506 which ensures good and reliable electrical connection with the detonator assembly upon tubular make-up of the gun string (e.g., again referring to
Alternate embodiments of the electrical contact 380 are also possible, for example, wherein the bends 422 are not identical (e.g., not having the same 2D distance 446, referring to
Also shown by the figure is how at least a portion of the end alignment 390 may be seated within the charge tube 312. One purpose (among many) of the end alignment is to centralize the charge tube 312 within the gun body 316 such that the charge tube 312 and the gun body 316 do not touch. For example, the end alignment 390, which may be made of an electric insulating material (e.g., plastic) may physically and/or electrically separate the charge tube 312 from the gun body 316 such that the charge tube 312 is sheltered from the surrounding environment (e.g., the wellbore 110 of
As shown and described in previous figures, the perforating gun 310 comprises an end alignment 390. The end alignment 390 is a multipurpose device which, among other things, provides a secure space, through which the electrical detonation signal passes safely and unhindered by external influences (e.g., detonation, wellbore 110 of
The end alignment 390 may be unitarily formed as one piece, such as by injection molding, additive manufacturing (i.e., 3D printing), or the like. Alternatively, one or more components of the end alignment 390 (e.g., including the collet 602 and lug 604) may be separately attached to the end alignment 390, such as but not limited to over molding, fastening, snap fitting, or other methods of joining. The end alignment 390 may comprise any suitable electrically insulating material, such as plastic, provided that it has sufficient strength to resist breaking.
A periphery 628 of the end alignment 390 may define an outer diameter of end alignment 390. The periphery 628 may include a plurality of non-contiguous peripheral portions, e.g., ears 610a, 610b, 610c, etc., circumferentially spaced along a generally circular profile indicated by a dashed line at 628 that may conform to an inner diameter of a charge tube or other outer perforating gun component (e.g., gun body 316 of
As previously mentioned, the skeletonized body of the end alignment 390, i.e., having one or more significant portions removed as cut-outs 614, aids in material reduction while not significantly compromising integrity or functionality of the end alignment 390. This functionally limits the amount of material used, resulting in a smaller footprint, as well as the total cost (e.g., by as much as 30%) of the piece than what would otherwise be achieved without the skeletonizing of the end alignment 390. As illustrated, cut-outs 614 are also formed between ears 610a, 610b, 610c, etc., to reduce the amount of space occupied by the end alignment 390.
Also visible in
As illustrated, the end alignment 390 may comprise a collet 602 and lug 604. The collet 602 and lug 604 may provide an ergonomic way to assemble which may, in some examples, not rely on external screws or fasteners that add time, additional cost, and difficulty of assembly. Specifically, the collet 602 and lug 604 facilitate assembly by allowing, for example, a single acceptable radial orientation of the end alignment 390 relative to a central axis of the charge tube 312 and/or perforating gun 310.
During assembly, the narrow portion 620 of the outer tubular body of the end alignment 390 is inserted into the charge tube 312 (e.g., referring to
All the disclosed methods of joining are an integral part in the design, however, while only a few specific configurations are shown, it should be understood that the scope of the present disclosure is intended to encompass any combination of the various features herein described. Alternative or additional fastening methods to the collet 602 and lug 604 may comprise, for example, interference fits, press fits, snap fit designs, living hinges, twist lock designs, transition fits, combinations thereof, and the like. In an alternative example, lug 604 may instead comprise more than one lug, e.g., a double lug. For example, two lugs may be spaced as a pair of lugs proximate the other. Alternatively, a first lug may be disposed on one circumferential location of the end alignment 390 and a second lug disposed on another circumferential location of the end alignment. Use in this manner may, in some examples, provide yet additional differential stability to the end alignment 390 and/or the one or more gun components attached thereto.
As mentioned previously, during assembly, the narrow portion 620 of the outer tubular body of the end alignment 390 is inserted into the charge tube 312 until the charge tube 312 is met by the contact surface 624 at the appropriate insertion distance. However, it is contemplated that an alternative configuration could be to have the narrow portion 620 be wider than the charge tube 312 so that the charge tube 312 instead inserts into the end alignment with the collet 602 flipped and the lug 604 disposed on an inner diameter of the outer tubular body of the end alignment 390 rather than on the outer diameter as illustrated. In such an embodiment, the narrow portion 620 (now modified to be the larger portion) of the outer tubular body of the end alignment 390 would fit around an outer surface of the charge tube 312, and the wider portion 622 (now the narrower portion) comprising the ears 610 would still function as the “stop,” i.e., contact surface 624, to limit over-insertion.
Likewise, it should be understood that the opening 608 and lug 604 may be located at various alternative circumferential position of the charge tube 312 to those shown by the figures. In some example configuration, the lug 604 itself may double as both the lug 604 and a collet 602, wherein the aperture is just past the end of the j-slot, and wherein the lug is configured (e.g., slanted or rounded) to slide into the aperture upon rotation of the end alignment 390 to its maximum stroke length. The end alignment 390 may also include various alternative features (e.g., double lug, dual collets, collet and lug combinations); various alternative electrical connections; various alternative detonator housing designs (e.g., different collet lengths, different methods of manufacturing, multi-part pieces, detonating cord stop feature of varying size, shape, location, number of protrusions); and collet 602 and lug 604 may be alternatively axially snapped into place, i.e., not twisted.
One or more aspects of the present disclosure may be used in various commercial gun systems to increase service quality and reliability of such systems and related products. These features may also be compatible with various third party equipment, may increase the likelihood for a reliable electrical connection downhole, maintain good service quality, and serve to maintain the reputation of established products while reducing non-productive time (NPT) at the work site. Also, as this design may in some examples not rely on additional fasteners, there may also be a potential cost reduction due to the removal of additional external fasteners which would ordinarily be required when designing a perforating gun.
Accordingly, the present disclosure may provide an electrical contact for a perforating gun and related apparatus, systems, and methods, which may have improved downhole reliability. The methods, systems, and tools may include any of the various features disclosed herein, including one or more of the following statements.
Statement 1: An electrical contact comprising: a contact plate; a support plate; and three or more bends disposed between the contact plate and the support plate to counteract a force applied to the contact plate when engaged by a contact pin, wherein the electrical contact is configured to convey a detonating signal through an electrical feedthrough extending through at least a bulkhead of two or more perforating guns.
Statement 2: The electrical contact of statement 1, further comprising two or more exterior fins for maintaining axial contact with the contact pin.
Statement 3: The electrical contact of statement 2, wherein the two or more exterior fins are disposed about the support plate, wherein an outer diameter of the support plate and the two or more exterior fins is greater than a two-dimensional linear dimension of the three or more bends.
Statement 4: The electrical contact of any of statements 1-3, wherein a two-dimensional linear dimension of the three or more bends is approximately equal to an outer diameter of the support plate not including exterior fins.
Statement 5: The electrical contact of any of statements 1-4, wherein the electrical contact is further configured to convey the detonating signal through an end alignment to a detonator via a mandrel and a spring.
Statement 6: The electrical contact of any of statements 1-5, wherein the electrical contact comprises an electrical connector and a wire connector, wherein the electrical connector and the wire connector are joined at a mating connection.
Statement 7: The electrical contact of statement 6, wherein the mating connection comprises one or more crimped connections.
Statement 8: The electrical contact of statement 6, wherein the mating connection comprises a mating end of the electrical connector inserted into a quick connect positive lock receptacle of the wire connector.
Statement 9: The electrical contact of statement 6, wherein a mating end of the electrical connector comprises one or more protrusions, and wherein the one or more protrusions are configured to contact a stop of the wire connector.
Statement 10: The electrical contact of any of statements 1-9, wherein the electrical contact consists of a single unitarily formed piece.
Statement 11: A method comprising: disposing two or more perforation guns into a wellbore extending into a subterranean formation, wherein the two or more perforation guns are electrically coupled by an electrical contact and a contact pin, the electrical contact comprising: a contact plate; a support plate; and three or more bends disposed between the contact plate and the support plate to counteract a force applied to the contact plate when engaged by the contact pin.
Statement 12: The method of statement 11, wherein the electrical contact further comprises two or more exterior fins for maintaining axial contact with the contact pin.
Statement 13: The method of statement 12, wherein the two or more exterior fins are disposed about the support plate, wherein a diameter of a circumferential profile formed by the two or more exterior fins is greater than a two-dimensional linear dimension of the three or more bends.
Statement 14: The method of any of statements 11-13, wherein a two-dimensional linear dimensions of the three or more bends is approximately equal to or less than a diameter of the support plate not including exterior fins.
Statement 15: The method of any of statements 11-14, further comprising passing a detonation signal through an electrical feedthrough extending through a bulkhead and an end alignment of at least one of the two or more perforating guns with at least the electrical contact, wherein the electrical contact is in electrical communication with the contact pin.
Statement 16: The method of any of statements 11-15, wherein the electrical contact comprises an electrical connector and a wire connector, wherein the electrical connector and the wire connector are joined at a mating connection.
Statement 17: The method of statement 16, wherein the mating connection comprises one or more crimped connections, and wherein the mating connection comprises a mating end of the electrical connector inserted into a quick connect positive lock receptacle of the wire connector.
Statement 18: The method of any of statements 11-17, wherein the contact pin comprises, or is attached to, a spring and a mandrel.
Statement 19: A method of assembling a perforating gun string, the method comprising: securing a plurality of perforating charges at different positions and firing orientations along a charge carrier; securing an end alignment between the charge carrier and a bulkhead, the end alignment and bulkhead comprising an electrical feedthrough; disposing an electrical contact within the electrical feedthrough, the electrical contact comprising a contact plate, a support plate, and three or more bends disposed between the contact plate and the support plate, and engaging the contact plate with a contact pin, wherein the electrical contact and the contact pin are configured to transmit a detonation signal between a first perforating gun and a second perforating gun for detonating the perforating gun string.
Statement 20: The method of statement 19, wherein the electrical contact further comprises two or more exterior fins disposed about the supporting plate or the contact plate.
For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.
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