Alignment Sub for Perforating Gun Charge Orientation

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Solution Overview

Problem

In oil and gas operations, wellbore tools with perforating guns often fail to consistently orient shaped charges, leading to uneven perforation sizes and tortuous fractures, which can impede hydrocarbon flow and increase the risk of premature screen-out during hydraulic fracturing.

Innovation Solution

An alignment sub assembly is introduced, comprising a first and second sub body with rotatable coupling, bulkhead pins, and a locking mechanism, to ensure aligned perforations by securing and orienting shaped charges in wellbore tools, thereby maintaining consistent perforation sizes regardless of charge direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wellbore tools are connected in tool strings to reduce time and costs, then productivity is improved, but alignment precision of shaped charges deteriorates

Engineering Contradiction:

Improveoperation efficiencyVSAvoidcharge alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The alignment sub acts as an intermediary component between adjacent perforating guns in the tool string. It includes alignment features such as pins and recesses that mechanically couple the guns while maintaining precise angular alignment, ensuring that shaped charges across multiple guns are properly phased despite the modular connection approach

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The alignment sub incorporates pre-configured alignment features and indexing mechanisms that establish correct charge alignment before the perforating operation begins. The mechanical coupling features are designed to automatically orient the guns correctly when connected, eliminating the need for post-assembly alignment adjustments

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If shaped charges are oriented in different directions, then adaptability is improved, but perforation consistency deteriorates

Engineering Contradiction:

Improvecharge orientation flexibilityVSAvoidperforation size consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The alignment sub employs asymmetric alignment features including keyed interfaces and non-circular coupling geometries that allow the system to accommodate charges oriented in different directions while maintaining consistent perforation outcomes. The asymmetric design ensures proper phasing regardless of the specific orientation configuration

Inventive Principle:

Principle #4Asymmetry

3Ease of operation

If wellbore tool string rests on lower horizontal surface, then ease of operation is improved, but perforation quality deteriorates

Engineering Contradiction:

Improvetool positioningVSAvoidperforation uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The alignment sub serves as a mediator between the tool string and the wellbore environment, providing a reference framework that maintains proper charge orientation even when the tool string settles on the wellbore surface. The alignment features compensate for positional variations caused by resting on the horizontal surface

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11988049B2Alignment sub and perforating gun assembly with alignment sub

Publication Date: 2024.05.21 DYNAENERGETICS EURO GMBH

AI summary

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.