Penetrator and dispenser and method of use

Abstract

A dispenser includes: a body defining a chamber and a chamber in communication with each other; and a penetrator assembly, wherein the penetrator assembly is configured to be accommodated in the cavity. The penetrator assembly comprises: a penetrator; a propellant, the propellant being operably positioned relative to the penetrator; an exploder, the exploder being in operable communication with the propellant; and an electrical conductor configured and arranged to deliver electrical power to the initiator. The dispenser may be in a downhole location, such as a wellbore, and the penetrator assembly may be launched such that the penetrator perforates in a casing of the wellbore.

Description

Technical Field

[0001] Embodiments of the present invention generally relate to downhole systems, components, and methods. One or more particular embodiments relate to devices and methods for dispensing explosive perforating charges associated with downhole operations such as fracturing. Background Art

[0002] In a conventional hydraulic fracturing process, a perforating gun, a setting tool, and a packer are lowered into a wellbore. This particular assembly is on a wireline and pumped down into the wellbore. Once the assembly reaches a predetermined destination, the packer is set and sealed to the wellbore casing by the setting tool. Then, the wireline will begin to pull the perforating gun and the setting tool out of the wellbore and start firing high-explosive shaped charges into the wellbore casing, thereby creating perforations within approximately 200 feet of the most recently set packer.

[0003] The perforating gun may include multiple sub-assemblies, or "joints," connected to each other. The length of each joint can be between one foot and two feet, and each joint can carry up to three to six shaped charges. In a 200-foot perforation zone downhole (also known as a fracture stage), there may be thirty to sixty perforations. This means that each stage of the fracturing may require multiple perforating gun joints, which when connected together, can form an assembly up to 30 feet long.

[0004] Using conventional processes and equipment, once a shaped charge is fired from an existing perforating gun, any tool located below (i.e., downhole) the fired shaped charge cannot receive power anymore due to damage caused by the explosive perforating charge. Additionally, once a shaped charge is fired, it will destroy all components inside the perforating gun joint. Therefore, once one or more perforating charges are fired, the perforating gun joint cannot be reused. Brief Description of the Drawings

[0005] To describe the manner in which at least some of the advantages and features of the present invention are achieved, embodiments of the present invention will be described in more detail with reference to specific embodiments of the present invention shown in the accompanying drawings. It should be understood that these drawings only depict typical embodiments of the present invention and should not be considered as limiting its scope. Embodiments of the present invention will be described and explained with additional specificity and detail by using the drawings.

[0006] Figure 1 Aspects of some example penetrators are disclosed.

[0007] Figure 2 Aspects of an example penetrator assembly are disclosed.

[0008] Figure 3 Aspects of an example penetrator assembly are disclosed.

[0009] Figure 4 Aspects of an example penetrator assembly are disclosed.

[0010] Figure 5 Aspects of an example penetrator including a jacket are disclosed.

[0011] Figure 6 、 Figure 7 、 Figure 8 、 Figure 9a and Figure 9b Example operations during firing of a penetrator assembly and associated structures and devices are disclosed.

[0012] Figure 10 An example computing entity is disclosed that is configured and operable to perform any of the disclosed computer-implemented methods, processes, and operations. DETAILED DESCRIPTION

[0013] Embodiments of the present invention generally relate to downhole systems, components, and methods. One or more particular embodiments relate to devices and methods for dispensing explosive perforating charges associated with downhole operations such as fracturing. Such devices can include, but are not limited to, perforating guns and other dispensers, and associated explosive perforating charges, including penetrators in the form of shaped charges, for example.

[0014] An example embodiment includes a dispenser configured to carry one or more penetrators, for example to one or more downhole locations. The dispenser can take the form of a component separate from the perforating gun but configured to connect to the perforating gun, or can be integrated into the perforating gun as an element of the perforating gun. In one embodiment, the dispenser can be used in place of the perforating gun. In one embodiment, the penetrator assembly can include various elements such as an ignition power line, a penetrator, a propellant, and a detonator. In one embodiment, the penetrator can be made of various materials, which can include high molecular weight materials. In one embodiment, the penetrator assembly can be loaded into a dispenser chamber bore of the dispenser as a single complete unit. The type of penetrator assembly and penetrator can vary depending on considerations such as downhole conditions and the downhole operation(s) to be performed. In one embodiment, different types of penetrator assemblies can be deployed together in a single dispenser. In one embodiment, the penetrators can be arranged within the dispenser in various different orientations.

[0015] In one embodiment, when a dispenser having a penetrator assembly is in place downhole, the penetrator assembly can be fired by applying current to the ignition power line. After firing the associated penetrator assembly, the penetrator can create openings of various sizes and types in the well casing and formation in which the dispenser is deployed. In one embodiment, multiple penetrator assemblies of the dispenser can be fired sequentially, or all at the same time, and / or in any other manner. In one embodiment, the dispenser can be configured such that firing one or more penetrator assemblies in the dispenser does not cause any substantial damage to the dispenser, such that the dispenser can be reloaded with one or more penetrator assemblies and used again.

[0016] Embodiments of the present invention, such as the examples disclosed herein, can be beneficial in several respects. For example, and as will be apparent from the present invention, one or more embodiments of the present invention can provide one or more advantageous and unexpected effects in any combination, some examples of which are described below. It should be noted that these effects are neither intended nor should they be construed as limiting the scope of the claimed invention in any way. It should also be noted that nothing in this document should be construed as constituting an essential or indispensable element of any invention or embodiment. Instead, the various aspects of the disclosed embodiments can be combined in various ways to define further embodiments. For example, any element(s) of any embodiment can be combined with any element(s) of any other embodiment to define a further embodiment. Such further embodiments are considered to be within the scope of the present invention. Similarly, any embodiment included within the scope of the present invention should not be construed as solving or being limited to solving any particular problem(s). Any such embodiment should also not be construed as achieving or being limited to achieving any particular technical effect(s) or solution(s). Finally, no embodiment is required to achieve any of the advantageous and unexpected effects disclosed herein.

[0017] For example, one advantageous aspect of one embodiment is that the dispenser can be configured to be usable for multiple operations and not be substantially damaged or destroyed by the firing of one or more penetrator assemblies. As another example, one or more embodiments can provide penetrators of various different geometries to achieve different corresponding effects. Various other advantages of one or more example embodiments will be apparent from the present invention.

[0018] A. Overview of Aspects of Example Embodiments

[0019] One embodiment may include a dispenser that can be used in place of a conventional perforating gun or can also be used as a supplement to a conventional perforating gun. The dispenser can be made of various materials including, but not limited to, 4330 vanadium-modified steel, as well as 4340 steel and 4340 vanadium-modified steel.

[0020] The dispenser can have a length of, for example, from about 25 inches to 50 inches. The length of an example dispenser can be less than 60 inches and can be configured to contain up to 70 penetrator assemblies, each penetrator assembly including a respective penetrator that can be used to penetrate or perforate a wellbore casing or other tubular member and / or the formation. Other embodiments of the dispenser can be configured to carry more or fewer penetrator assemblies. Due to the structure and / or operation of the penetrator assembly and / or the dispenser, electrical power can still be available at the downhole location of the dispenser once the penetrator assembly has been fired and communication can be maintained with a tool or other penetrator at the downhole location of the most recently fired penetrator even after the penetrator assembly has been fired.

[0021] In one or more embodiments of the present invention, the penetrator or other projectile can be made of a variety of materials. Example penetrator materials for one or more embodiments include, but are not limited to, tungsten, depleted uranium, steel, titanium, antimony, zinc, tin, copper, lead, rhenium, platinum, iridium, osmium, and any combination of these materials.

[0022] In one embodiment, the penetrator can be launched or otherwise projected out of the dispenser by igniting a controlled or rapid combustion of a propellant of the penetrator assembly using an electrical initiator or a mechanical initiator. The burning propellant can in turn generate gas that pushes the penetrator out of the dispenser. The gas can be pressurized by the geometry of the dispenser and / or the geometry of the penetrator assembly, which can be used to contain and direct the gas such that the gas exerts pressure on the penetrator, causing the penetrator to be pushed out of the dispenser.

[0023] In an example embodiment, the penetrator assembly can include an ignition power line, a penetrator, a propellant, and an initiator. The assembly can be designed, manufactured, and encapsulated as a single unit. In one embodiment, the ignition power line can pass through the center of the penetrator or be offset from the center of the penetrator, pass through the propellant, and be connected to an electrical or mechanical initiator. The ignition power line can also surround the penetrator, pass through the propellant, and be directly connected to an electrical or mechanical initiator.

[0024] In one embodiment, the penetrator assembly can be loaded into the dispenser as a single unit and pressed into the chamber bore (or simply "bore") of the dispenser. Once the penetrator assembly is so positioned, the ignition power line can pass through the top of the bore and connect to a bulkhead (a sealed electrical connector that is mechanical and creates a sealed barrier between two modules or downhole tools), a connector, or directly to a penetrator launch control board, which can include a PCB (printed circuit board). The penetrator launch control board can control when and where to launch the penetrator into the wellbore casing or wellbore tubular member. In one embodiment, the penetrator launch control board can receive signals or commands from, or be included within, the main control board.

[0025] In one embodiment, the specific type and geometry of the penetrator and propellant employed can depend on downhole characteristics and conditions. For example, in one embodiment, the penetrator can be configured such that when launched from the dispenser, the penetrator creates an oval hole in the wellbore casing and / or formation (such as rock). Additionally, a penetrator with such a configuration can be used as a wedge in the rock to facilitate rock fracture at a lower fracture pressure, while also maximizing the flow area of the fracture and minimizing the reduction in the strength of the casing that the penetrator may partially or fully pass through.

[0026] As another example, a penetrator according to one embodiment can be configured such that when launched from the dispenser, the penetrator creates an ovoid hole in the wellbore casing and / or formation (such as rock). Additionally, a penetrator with such a configuration can be used as a wedge in the rock to facilitate rock fracture at a lower fracture pressure, while also maximizing the flow area of the fracture and minimizing the reduction in the strength of the casing that the penetrator may partially or fully pass through.

[0027] A penetrator according to another embodiment can be configured to create a smooth round hole, which can be used as an orifice to allow for precise calculation of the fluid flow rate and velocity through the perforation. In this way, the flow through each perforation can be designed and controlled.

[0028] As a final example, a penetrator according to yet another embodiment of the present invention can have a geometry such that the penetrator causes or facilitates the penetrator to travel at a specific angle and / or path after launch. By way of illustration, the penetrator and / or dispenser can be configured such that when the penetrator contacts the casing or any hard surface after the penetrator assembly is launched, the penetrator rotates at a specific angle (such as approximately 45 degrees) and continues to penetrate the casing, formation, and / or other structure(s) at that angle. Additionally, the inclined path that the penetrator travels, i.e., a path that is inclined relative to the radial or longitudinal axis of the wellbore casing, can reduce perforation friction and erosion.

[0029] It should be understood that different penetrator / dispenser implementations may still have common configurations and components, such as explosive type, propellant and materials, and penetrator geometry. Thus, unless a component or configuration is explicitly identified as being for only a particular (one or more) penetrator / dispenser type, it should be understood that such components and configurations may also be used in other penetrator / dispenser implementations.

[0030] B. Exemplary Implementations of Penetrators

[0031] Now note Figure 1 , the geometries of various exemplary penetrators are disclosed. For optimal penetration and hole geometry, the geometry of an exemplary dispenser penetrator according to some implementations may be important for certain operations. The geometry of the penetrator can make the hole size smooth and consistent, thereby allowing for reduced frictional losses on the hole during operations such as fracturing. In one implementation, the length of the penetrator can be in the range of 0.5 inches to 1.00 inches.

[0032] B.1 Straight Edge Penetrator (SEP)

[0033] In Figure 1 , an exemplary implementation of the SEP is designated by 102. As shown, the SEP 102 can include a generally cylindrical portion 102a and a generally conical portion 102b. The cylindrical portion 102a and the conical portion 102b can be integral with each other and together formed from a single piece of material. The SEP 102 can define a channel 102c through which wires and / or other components can extend into and / or through.

[0034] More specifically, the SEP 102 can be made in solid form from one material or a combination of materials (such as the materials or material combinations disclosed herein). The solid SEP can be machined, compressed, cast, molded, extruded, or printed. In one implementation, for example, the outer diameter of the SEP 102 can be about 0.450 inches, 0.500 inches, or 0.550 inches. As described above, the SEP 102 can include a channel 102c that extends through a part or all of the SEP 102. In one implementation, the channel 102c can have a generally circular cross-section, for example with an inner diameter of about 1 / 16 inch, 1 / 8 inch, or 1 / 4 inch. The channel 102c can be sized and configured such that a wire can pass through the SEP 102 and be connected to an electrical or mechanical initiator located below the SEP 102. In one implementation, the channel 102c can accommodate various materials. Such materials can include, but are not limited to, propellant or combustible materials, components, or chemicals that can reside or adhere to the inner diameter of the channel 102c.

[0035] One or more embodiments of SEP 102 may be made of, but are not limited to, the following materials: tungsten alloys, including molybdenum tungsten alloys, niobium tungsten alloys, vanadium tungsten alloys, and hard metals or tungsten carbide. Tungsten may contain elements such as, but not limited to, copper, cobalt, nickel, iron, and chromium. According to one embodiment, other example materials for SEP 102 include, but are not limited to, depleted uranium, uranium 238, materials including steel, titanium, antimony, zinc, tin, copper, lead, rhenium, platinum, iridium, and osmium, and any combination of these materials.

[0036] In one embodiment, SEP 102 may also include a casing or armor that may be made of any one or a combination of the materials of SEP 102 described above. The casing or armor may be separate from or integral with the cylindrical portion 102a and / or the conical portion 102b.

[0037] In one embodiment, the armor (see Figure 5 ) may be filled with a material or combination of materials, such as the materials for the penetrator disclosed herein. The armor may be formed in various ways. For example, the armor may be machined, molded, cast, printed, extruded, sintered, or pressed. The armor may be pressed onto the cylindrical portion 102a and / or the conical portion 102b, or otherwise attached to the cylindrical portion 102a and / or the conical portion 102b. The armor may be subjected to post-treatment, such as hardening, acid treatment, or heat treatment, after being attached to the projectile.

[0038] B.2 Round Edge Penetrator (REP)

[0039] Continuing to note Figure 1 , an example embodiment of the REP is designated 104. Except as described below, the dimensions, materials, manufacturing processes, and configurations of the REP 104 may be similar or identical to those of the SEP 102. As shown, the REP 104 may include a generally cylindrical portion 104a and a rounded generally conical portion 104b. The cylindrical portion 104a and the conical portion 104b may be integral with each other and together formed from a single piece of material. The REP 104 may define a channel 104c through which a wire and / or other components may extend into and / or through.

[0040] B.3 Double Edge Penetrator (DEP)

[0041] As Figure 1Further disclosed in [reference], an exemplary embodiment of the DEP is denoted by 106. Except as described below, the dimensions, materials, manufacturing processes, and configurations of the DEP 106 may be similar to or the same as those of the SEP 102. As shown in the figure, the DEP 106 may include a generally cylindrical portion 106a, a first edge portion 106b, and a second edge portion 106c. As shown, the first edge portion 106b and the second edge portion 106c may be adjacent to each other. The first edge portion 106b and the second edge portion 106c may each include a surface having a conical shape, which is inclined at a certain angle with respect to the imaginary vertical Y-axis. As shown, the respective inclination angles of these surfaces may be different from each other. The portion 106a, the first edge portion 106b, and the second edge portion 106c may be integrally formed with each other and jointly formed of a single piece of material. The DEP 106 may define a channel 106d through which wires and / or other components may extend into and / or through.

[0042] B.4 Cutting Edge Penetrator (CEP)

[0043] As Figure 1 Further disclosed in [reference], an exemplary embodiment of the CEP is denoted by 108. Except as described below, the dimensions, materials, manufacturing processes, and configurations of the CEP 108 may be similar to or the same as those of the SEP 102. As shown in the figure, the CEP 108 may include a generally cylindrical portion 108a and a generally conical portion 108b. In one embodiment, the maximum outer diameter of the generally conical portion 108b may be less than the outer diameter of the generally cylindrical portion 108a, thereby defining a step at the intersection of the generally conical portion 108b and the generally cylindrical portion 108a.

[0044] The generally conical portion 108b and the generally cylindrical portion 108a may be integrally formed with each other and jointly formed of a single piece of material. The CEP 108 may define a channel 108c through which wires and / or other components may extend into and / or through.

[0045] C. Exemplary Embodiments of the Penetrator Assembly

[0046] Now turning to Figure 2 , an exemplary penetrator assembly according to an exemplary embodiment of the present invention is denoted by 200. The exemplary penetrator assembly 200 may include a detonator wire 202, a penetrator 204, a propellant 206, and a detonator 208.

[0047] The penetrator 204 can include any penetrator disclosed herein. In one embodiment, the penetrator 204 can be molded or otherwise attached to the propellant 206. In one embodiment, the penetrator 204 and the propellant 206 can be housed within a cartridge, casing, or other housing, or they can be unhoused. Thus, for example, in a caseless configuration of the penetrator 204 and the propellant 206, there may be no cartridge or housing that needs to be ejected once the penetrator assembly 200 is fired. That is, the penetrator assembly 200 can be manufactured and fired without the use of a cartridge or housing to hold the penetrator 204 and the propellant 206. In one embodiment, the penetrator 204 can be solid or can define a channel through which the initiator wire 202 passes. Further details regarding the exemplary initiator wire 202 are set forth below.

[0048] In one embodiment, the initiator wire 202 can be attached to a harness that is connected to a connector, which in turn can be connected to a bulkhead or directly to a penetrator firing control board. In one embodiment, the initiator wire 202 can pass through the penetrator 204, such as through a channel defined by the penetrator 204, and can also pass through the propellant 206, and then be connected to and terminate at the initiator 208. In one embodiment, the initiator wire 202 can be used, for example, to send a command signal to the initiator 208 to activate the initiator 208, and then the initiator 208 can ignite the propellant 206.

[0049] Continuing with reference Figure 2 to the example, the propellant 206 can include high-energy materials, munitions, or explosives that can withstand high temperatures (e.g., above 100 degrees Celsius) and high pressures (e.g., about 10 K psi (pounds per square inch)) without becoming unstable or detonating or burning prematurely. Example propellants 206 that can be used in one embodiment of the present invention include, but are not limited to, RDX (sometimes referred to as "cyclonite") - an organic compound with the chemical formula (O 2 N 2 CH 2 ) 3 , and HMX (sometimes also referred to as "octogen") - a high-energy nitramine explosive chemically related to RDX. The propellant 206 can include fast-burning propellants or slower, controlled-burning propellants.

[0050] In one embodiment, the propellant 206 can be in powder form and be shaped or molded such that its shape can conform to the penetrator 204 and the chamber defined by the dispenser (see Figure 3) is adapted to the geometry. More specifically, the conforming propellant 206 and the relatively wide chamber can contribute to achieving a higher penetrator velocity. Similarly, since the propellant 206 can be shaped, adapted, and compressed into the propellant chamber, making the shape of the propellant 206 match the internal geometry of the chamber, thereby reducing the amount of space in the bore occupied by the propellant 206, the effective length of the bore defined by the dispenser (see Figure 3 ) can be increased.

[0051] Finally, the initiator 208 can be used to ignite the propellant 206, and in one embodiment, the initiator can be included within the propellant 206, as Figure 2 shown. As previously described herein, the initiator 208 can be activated by, but not limited to, being commanded by an electrical signal, various currents, or mechanical actuation.

[0052] D. Example Embodiment of a Penetrator Assembly Installed in a Chamber

[0053] Now note Figure 3 , which discloses an example penetrator assembly 300 that is installed in a chamber 400 of a dispenser. In one embodiment, the penetrator assembly 300 can include any of the disclosed penetrator assemblies. Thus, the example penetrator assembly 300 can include a penetrator 302, a propellant 304, and an initiator 306, and an initiator wire 308 can be connected to the initiator 306.

[0054] Generally speaking, and as Figure 3 shown, the penetrator assembly 300 can be installed in a chamber within the bore 402 defined by the dispenser, and the penetrator assembly 300 can remain in that position until it is dispensed, that is, until the penetrator of the penetrator assembly 300 is launched. Various methods can be used to place the penetrator assembly 300 in the bore 402. For example, the penetrator assembly 300 can be placed in the bore 402 pneumatically, hydraulically, or mechanically compressed. In one embodiment, the chamber 400 can include a housing or block that includes one or more bores 402.

[0055] In one embodiment, the bore 402 can be sized and configured to accommodate multiple penetrator assemblies 300 of the same or different sizes and lengths. The bore 402 can be honed, machined, and / or otherwise manufactured to achieve optimal performance of the penetrator assembly 300. After the penetrator 302 is launched, the bore 402 can be reloaded with another penetrator assembly 300 one or more times.

[0056] A propellant chamber 404 that communicates with the bore 402 can be defined. As Figure 3As shown, the propellant chamber 404 can accommodate propellant 304 and initiator 306. In one embodiment, the bottom of the propellant chamber 404 can serve as a baffle to ensure that the energy generated when the propellant 304 is ignited is applied in the direction of penetrator 302. This baffle can help ensure that after one or more penetrators 302 are fired through the barrel 402, the barrel 402 remains within its dimensional tolerances.

[0057] Finally, the exemplary chamber 400 can include a wire groove 406. In one embodiment, the wire groove 406 can include a groove that can be machined or otherwise produced on the top of the barrel 402 to allow the initiator wire 308 to pass through the barrel 402 or the chamber of the dispenser unobstructed.

[0058] E. Exemplary Embodiments of the Propellant Chamber

[0059] Now referring Figure 4 , unless otherwise specified in the following discussion, Figure 4 the exemplary penetrator assembly 500 and chamber 600 can be similar or identical to the exemplary penetrator assembly 300 and chamber 400, respectively.

[0060] As Figure 4 shown, the exemplary chamber 600 can include a propellant chamber 602. The propellant chamber 602 can accommodate the propellant and initiator of the penetrator assembly 500. In one embodiment, the propellant chamber 602 can be sized and configured such that the inner diameter of a portion of the propellant chamber 602 is greater than the inner diameter of the barrel 604 of the chamber 600. The relatively wide propellant chamber 602 can provide a relatively large volume to compress more propellant. That is, compared to the case where the propellant chamber 602 has the same inner diameter as the barrel 604, the propellant chamber 602 can accommodate a larger volume of propellant or energetic material. This configuration of the propellant chamber 602 can enable the chamber 600 to employ a relatively long barrel 604, thereby enabling the penetrator fired from the barrel 604 to have a relatively high velocity.

[0061] F. Exemplary Embodiments of Dissolvable Penetrators

[0062] Next turning to Figure 5 , an exemplary embodiment of a dissolvable penetrator is designated by 700. Generally, the exemplary dissolvable penetrator 700 can include a body 702 on which a jacket 704 can be provided. In one embodiment of the present invention, the body 702 can include any penetrator material disclosed herein.

[0063] In another embodiment of the present invention, the body 702 can comprise or consist of a dissolvable material (such as a dissolvable alloy). The dissolvable alloy can include, for example, magnesium, aluminum, or a combination of these. The dissolvable material can be in solid form and compressed into or adapted to the interior of the sabot 704. The dissolvable material can also be poured into the sabot 704 and solidified. The dissolvable material can also be in powder form and compressed to conform to the interior shape of the sabot 704. In one embodiment, the (one or more) dissolvable alloys can be converted to a molten state and poured into a mold and compressed into the desired shape, which may or may not be the shape of the body 702. In one embodiment, the (one or more) dissolvable alloys can be forged or sintered after molding, for example, forged or sintered into the final shape, which can be the shape of the body 702. Once the body 702 has been formed, the body 702 can then be clad, coated, or otherwise covered by the sabot 704, which can include but is not limited to a tungsten sabot, a depleted uranium sabot, a steel sabot, and a nickel alloy sabot, or any combination of these materials.

[0064] In one embodiment, once the penetrator 700 has been launched, the dissolvable material can dissolve or begin to dissolve. More specifically, after the penetrator 700 has been launched and penetrated the casing, cement, and / or formation, the dissolvable material of the body 702 can begin to dissolve. The dissolvable material of the body 702 will begin to break down after the body 702 has fragmented, for example, after the penetrator 700 has penetrated the casing and / or other structures. That is, after launch, the penetrator 700 initially penetrates one or more elements, then the penetrator 700 fragments, and the body 702 begins to break down and dissolve.

[0065] In certain applications, a penetrator 700 having a dissolvable body 702 may be desired. For example, since the body 702 can break down after the penetrator 700 has been launched, the problem of a solid penetrator falling back down the wellbore through the perforations can be avoided. Instead, the fragments of the penetrator 700 can remain in the formation and break down. The temperature and pressure in the downhole environment can help to accelerate the dissolution process of the penetrator 700.

[0066] G. Exemplary Operational Aspects of One Embodiment of the Present Invention

[0067] Now note Figure 6 - FIG. 9, in which details of some operational aspects (including the ignition sequence) of one embodiment of the present invention are provided. First refer to Figure 6, the exemplary penetrator assembly is denoted by 1000 and includes a penetrator 1002, a propellant 1004, an initiator 1006, and an initiator wire 1008. The penetrator assembly 1000 can be installed in the chamber 1100 of a dispenser. In one embodiment, the dispenser can include a plurality of chambers 1100, and each chamber can accommodate a corresponding penetrator assembly 1000.

[0068] As Figure 6 shown, an electrical signal "E" can be emitted, for example, by an ignition circuit board, and the emission passes through the initiator wire 1008 to activate the initiator 1006. More specifically, now referring to Figure 7 , the initiator 1006 can be activated upon receiving the electrical signal "E". In response to receiving the electrical signal "E", the initiator 1006 can ignite the propellant 1004. The ignition of the propellant 1004 can cause the propellant to burn, generating one or more gases 1008, and these gases will rapidly expand. The pressure generated by the expanding gas 1008 acts on the penetrator 1002 to force the penetrator 1002 out of the bore 1102 of the chamber 1100. The expansion of this gas 1008 can include a first gas expansion stage during the launch of the penetrator 1002.

[0069] Continuing to refer to Figure 7 , the expanding gas denoted as 1010 has expanded to the extent that it pushes the initiator wire 1008 out of the channel defined by the penetrator 1002, such that some of the expanding gas can now pass through the channel of the penetrator 1002 and leave the bore 1102. When this expanding gas passes through the bore 1102, the gas can expel any debris, fluid, or other material(s) that may be present in the bore 1102.

[0070] Next, turning to Figure 8 , a second gas expansion stage is disclosed, in which the gas 1010 continues to expand, thereby forcing the penetrator 1002 out of the bore 1102 or ejecting the penetrator 1002 from the bore 1102. As the gas 1010 continues to expand, the gas 1010 can leave the bore 1102, and the expanding gas 1012 can expel any fluid, debris, and / or other substance(s) (collectively referred to as 1200) that are present between the penetrator 1002 and a structure (such as a wellbore, casing, and / or formation) (see Figure 9a ). Thus, for example, the fluid 1200 may be pushed away from the bore 1102 by the gas 1012, resulting in the creation of a void, and then the void may be filled with gas / air generated by the expansion of the gas 1010 through the channel of the penetrator 1002.

[0071] Now referring to Figure 9a, the chamber 1100 of the exemplary dispenser is shown as being disposed within a wellbore casing 1300 or other downhole component that defines an interior 1302 after the penetrator 1002 is fired. In particular, with the propellant chamber and the chamber of the chamber 1100 now emptied, the expanding gas 1012 continues to push the penetrator 1002 into the wellbore casing 1300 such that the penetrator 1002 forms a hole or perforation in and possibly through the wellbore casing 1300.

[0072] As Figure 9a Further shown, due to the expansion of the gas 1012 discharged through the penetrator 1002, the fluid 1200 is discharged between the chamber of the chamber 1100 and the wellbore casing 1300. Similarly, any residual gas generated within the chamber of the chamber 1100 has also been discharged after the penetrator 1002 has been fully fired from the chamber.

[0073] Brief reference Figure 9b , the chamber 1100 of the dispenser is shown as being received within a carrier 1400 disposed within the casing 1300. The carrier 1400 can include any suitable structure(s), including one or more of the metals disclosed herein, configured to receive one or more penetrator assemblies. In Figure 9b the example of, the carrier 1400 includes two halves 1400a and 1400b that are releasably connected together.

[0074] H. Other aspects and example embodiments

[0075] The following are some further example aspects and embodiments of the present invention. These are presented only as examples and are not intended to limit the scope of the present invention in any way.

[0076] Embodiment 1. A dispenser, comprising: a body that defines a chamber and a chamber that communicate with each other; and a penetrator assembly configured to be received within the chamber and including: a penetrator; a propellant operably positioned relative to the penetrator; an initiator operably communicating with the propellant; and an electrical conductor configured and arranged to deliver electrical power to the initiator.

[0077] Embodiment 2. The dispenser according to any one of the preceding embodiments, wherein the penetrator assembly is one of a set of individually deployable penetrator assemblies carried by the dispenser.

[0078] Embodiment 3. The dispenser according to any one of the preceding embodiments, wherein the dispenser is sized and configured to fit within a well casing.

[0079] Embodiment 4. The dispenser of any preceding embodiment, wherein the penetrator defines a channel extending through the penetrator, and wherein the electrical conductor passes through the channel.

[0080] Embodiment 5. The dispenser of any of the preceding embodiments, wherein the penetrator, the electrical conductor, the propellant, and the initiator are integrated into a single unit.

[0081] Embodiment 6. The dispenser of any preceding embodiment, wherein the electrical conductor comprises a wire passing through or around the penetrator.

[0082] Embodiment 7. The dispenser of any preceding embodiment, wherein the propellant comprises a high explosive.

[0083] Embodiment 8. The dispenser of any of the preceding embodiments, wherein the penetrator comprises a metal component that dissolves upon being ejected from the dispenser when the dispenser is in a wellbore.

[0084] Embodiment 9. The dispenser of any preceding embodiment, wherein when the penetrator assembly is fired, the penetrator passes through the chamber.

[0085] Embodiment 10. A dispenser as described in any of the preceding embodiments, wherein the chamber is configured to removably accommodate the penetrator, and the chamber holds the penetrator in an appropriate position so that when the dispenser is operably located in the wellbore, the penetrator can be radially ejected into the wellbore casing.

[0086] Embodiment 11. The dispenser of any preceding embodiment, wherein the propellant generates a gas when the propellant burns.

[0087] Embodiment 12. The dispenser of any preceding embodiment, wherein a portion of the chamber comprises a propellant chamber, the propellant and the initiator being disposed within the propellant chamber when the penetrator assembly is positioned within the dispenser.

[0088] Embodiment 13. The dispenser of any preceding embodiment 2, wherein the geometry of the propellant is adapted to the internal geometry of the propellant chamber.

[0089] Embodiment 14. The distributor of any preceding embodiment, wherein the distributor defines a longitudinal axis that is substantially concentric with an axis of the wellbore when the distributor is disposed in the wellbore.

[0090] Embodiment 15. The dispenser according to any one of the foregoing embodiments, wherein when the propellant burns, the propellant generates gas.

[0091] Embodiment 16. The dispenser according to any one of the foregoing embodiments, wherein the dispenser is configured to be releasably connected to a perforating gun.

[0092] Embodiment 17. The dispenser according to any one of the foregoing embodiments, wherein when the dispenser is located in a wellbore casing and the penetrator is launched by ignition of the propellant, the penetrator exits the dispenser and partially penetrates the wellbore casing.

[0093] Embodiment 18. The dispenser according to any one of the foregoing embodiments, wherein in operation, the electrical conductor receives power and / or control signals from outside the dispenser or from a launch control board integrated within the dispenser.

[0094] Embodiment 19. A penetrator assembly comprising: a penetrator; a propellant operably positioned relative to the penetrator; a detonator in operable communication with the propellant; and an electrical conductor configured and arranged to deliver power to the detonator, wherein the penetrator assembly is configured to be received within a chamber of a dispenser.

[0095] Embodiment 20. The penetrator assembly according to Embodiment 19, wherein the penetrator is one of the following: a straight-edge penetrator; a round-edge penetrator; a cutting-edge penetrator; and a double-edge penetrator.

[0096] Embodiment 21. The penetrator assembly according to any one of Embodiments 19-20, wherein a first end of the electrical conductor is embedded within the propellant and the electrical conductor passes through the penetrator and extends from one end of the penetrator.

[0097] Embodiment 22. The penetrator assembly according to any one of Embodiments 19-21, further comprising a jacket disposed around a portion of the penetrator.

[0098] Embodiment 23. The penetrator assembly according to any one of Embodiments 19-22, wherein the detonator is embedded within the propellant.

[0099] Embodiment 24. A method for using the dispenser according to any one of Embodiments 1-18.

[0100] Embodiment 25. A method for using the penetrator assembly according to any one of Embodiments 19-23.

[0101] I. Example Computing Devices and Related Media

[0102] Embodiments disclosed herein may include the use of a special-purpose or general-purpose computer, which may include a launch control board disclosed herein, which includes various computer hardware or software modules, as discussed in more detail below. The computer may include a processor and a computer storage medium that stores instructions that, when executed by the processor and / or caused to be executed by the processor, perform any one or more of the methods disclosed herein, or any (one or more) part of any of the disclosed methods. In one embodiment, a computing system including any of the components disclosed herein may be operated to control the launch of one or more penetrator components, for example, by using a launch control board.

[0103] As described above, embodiments within the scope of the present invention also include a computer storage medium, which is a physical medium for carrying or storing computer-executable instructions or data structures. Such a computer storage medium may be any available physical medium accessible by a general-purpose or special-purpose computer.

[0104] By way of example and not limitation, such computer storage media may include hardware memories such as solid-state drives / devices (SSDs), RAM, ROM, EEPROM, CD-ROMs, flash memory, phase change memory (“PCM”), or other optical disk memories, magnetic disk memories, or other magnetic storage devices, or any other hardware storage device that can be used to store program code in the form of computer-executable instructions or data structures that can be accessed and executed by a general-purpose or special-purpose computer system to implement the functions disclosed in the present invention. Combinations of the above should also be included within the scope of computer storage media. Such media are also examples of non-transitory storage media, and non-transitory storage media also include cloud-based storage systems and architectures, but the scope of the present invention is not limited to these examples of non-transitory storage media.

[0105] Computer-executable instructions include, for example, instructions and data that, when executed, cause a general-purpose computer, special-purpose computer, or special-purpose processing device to perform a particular function or group of functions (e.g., launch one or more penetrator components). Thus, some embodiments of the present invention may be downloaded to one or more systems or devices from, for example, a website, a mesh topology, or other sources. Similarly, the scope of the present invention includes any hardware system or device that includes an application instance that includes the disclosed executable instructions.

[0106] Although the subject matter has been described in language specific to structural features and / or methodological steps, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or steps described above. Rather, the specific features, operations, processes, and steps disclosed herein are disclosed as example forms for implementing the claims.

[0107] As used herein, the terms "module" or "component" may refer to software objects or routines executing on a computing system. The various components, modules, engines, and services described herein may be implemented as objects or processes executing on a computing system, e.g., implemented as separate threads. Although the systems and methods described herein may be implemented in software, they may also be implemented in hardware, or a combination of software and hardware. In the present invention, a "computing entity" may be any computing system as previously defined herein, or any module or combination of modules running on a computing system.

[0108] In at least some cases, a hardware processor is provided that is operable to execute executable instructions for performing a method or process (e.g., the methods and processes disclosed herein). The hardware processor may or may not include elements of other hardware, such as but not limited to the computing devices and other systems and components disclosed herein.

[0109] In terms of the computing environment, embodiments of the present invention may be executed in a client-server environment, whether in a network environment or a local environment, or in any other suitable environment (e.g., a local computing environment at a well site). Suitable operating environments for some aspects of at least some embodiments of the present invention include cloud computing environments, where one or more of the client, server, and other machines may be present and running in the cloud environment.

[0110] Now briefly refer Figure 10 , Figure 1 - Figure 9 and / or any one or more entities disclosed or implied elsewhere herein may take the form of a physical computing device, or include a physical computing device, or be implemented on a physical computing device, or be hosted by a physical computing device. An example of a physical computing device is denoted by 1500.

[0111] In Figure 10 example, the physical computing device 1500 includes: a memory 1502, which may include one, some, or all of random access memory (RAM), non-volatile memory (NVM) 1504 (e.g., NVRAM), read-only memory (ROM), and persistent memory; one or more hardware processors 1506; a non-transitory storage medium 1508, a UI (user interface) device 1510; and a data memory 1512. One or more memory components 1502 of the physical computing device 1500 may take the form of solid-state drive (SSD) memory. Similarly, one or more applications 1514 may be provided, which include instructions executable by one or more hardware processors 1506 (e.g., a GPU (graphics processing unit)) to perform any operation or a part thereof disclosed herein.

[0112] Such executable instructions can take various forms. For example, the executable instructions include instructions executable to perform any method or a part thereof disclosed herein, and / or instructions executable / executable at any storage site (whether it is a local site of an enterprise or a cloud computing site, a client, a data center, a data protection site including a cloud storage site, or a backup server) to perform any function disclosed herein. Similarly, such instructions can be executed to implement any other operations and methods disclosed herein and any part thereof.

[0113] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. Thus, the scope of the present invention is indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A dispenser, include: a body defining a chamber and a bore communicating with each other; as well as a penetrator assembly configured to be received in the chamber and comprising: Penetrator; a propellant operably positioned relative to the penetrator; an initiator in operable communication with the propellant; and An electrical conductor is configured and arranged to deliver electrical power to the initiator.

2. The dispenser according to claim 1, in, The penetrator assembly is one of a group of individually deployable penetrator assemblies carried by the dispenser.

3. The dispenser according to claim 1, in, The distributor is sized and configured to fit within a well casing.

4. The dispenser according to claim 1, in, The penetrator defines a passage extending therethrough, and the electrical conductor passes through the passage.

5. The dispenser according to claim 1, in, The penetrator, the electrical conductor, the propellant, and the initiator are integrated into a single unit.

6. The dispenser according to claim 1, in, The electrical conductor includes a wire passing through or around the penetrator.

7. The dispenser according to claim 1, in, The propellant includes high explosive.

8. The dispenser according to claim 1, in, The penetrator includes a metal component that dissolves after being ejected from the dispenser when the dispenser is located in a wellbore.

9. The dispenser according to claim 1, in, When the penetrator assembly is fired, the penetrator passes through the chamber.

10. The dispenser according to claim 1, in, The chamber is configured to removably receive the penetrator, and the chamber holds the penetrator in position so that the penetrator can be radially fired into a wellbore casing when the dispenser is operably located in the wellbore.

11. The dispenser according to claim 1, in, When the propellant burns, the propellant generates gas.

12. The dispenser according to claim 1, in, A portion of the chamber includes a propellant chamber in which the propellant and the initiator are disposed when the penetrator assembly is positioned in the dispenser.

13. The dispenser of claim 12, in, The geometry of the propellant is adapted to the internal geometry of the propellant chamber.

14. The dispenser of claim 1, in, The distributor defines a longitudinal axis that is generally concentric with an axis of the wellbore when the distributor is disposed in the wellbore.

15. The dispenser of claim 1, in, When the propellant burns, the propellant generates gas.

16. The dispenser of claim 1, in, The dispenser is configured to be releasably connected to a perforating gun.

17. The dispenser of claim 1, in, When the dispenser is located in a wellbore casing and the penetrator is launched by ignition of the propellant, the penetrator passes out of the dispenser and partially through the wellbore casing.

18. The dispenser according to claim 1, wherein, in operation, the electrical conductor receives power and / or control signals from outside the dispenser or from a launch control board integrated within the dispenser.

19. A penetrator assembly, comprising: a penetrator; a propellant operatively positioned relative to the penetrator; a detonator operatively in communication with the propellant; and an electrical conductor configured and arranged to deliver power to the detonator, wherein the penetrator assembly is configured to be received within a chamber of a dispenser.

20. The penetrator assembly according to claim 19, wherein, the penetrator is one of the following: a straight-edge penetrator; a round-edge penetrator; a cutting-edge penetrator; and a double-edge penetrator.

21. The penetrator assembly according to claim 19, wherein, a first end of the electrical conductor is embedded within the propellant and the electrical conductor passes through the penetrator and extends from one end of the penetrator.

22. The penetrator assembly according to claim 19, further comprising a jacket disposed around a portion of the penetrator.

23. The penetrator assembly according to claim 19, wherein, the detonator is embedded within the propellant.

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