Self-selecting Switch Devices for Perforating Gun Systems
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Solution Overview
Problem
Conventional perforating gun systems face challenges in efficiently and reliably initiating multiple guns in a string, particularly in horizontal wells, due to limitations in existing systems such as Dual Diode Systems, Ballistic Delay Fuses, and Mechanical Switch Systems, which result in off-depth perforations, elevated failure rates, and the need for specialized control panels.
Innovation Solution
The implementation of self-selecting switch devices with microcontrollers, logic circuits, and switches that can detect the presence of other connected devices and selectively direct electrical current to detonators, allowing for precise initiation of perforating guns without the need for complex circuitry or specialized control panels, enabling bypass of misfired guns and efficient operation with conventional shooting panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical switch systems are used to initiate multiple perforating guns, then the system can operate with simple equipment, but the reliability is reduced due to elevated failure rates and off-depth perforations
Solution Approach 1:
The switch device automatically detects whether it is the last un-fired gun in the string and self-activates without requiring external control signals. The microcontroller monitors the circuit state and autonomously closes the switch when conditions are met, eliminating the need for complex external control panels and reducing operational complexity while maintaining high reliability
Solution Approach 2:
The patent replaces conventional mechanical switch systems with an electronic control system based on microcontrollers and logic circuits. This substitution eliminates the mechanical wear and failure modes of traditional switches while providing more reliable electronic detection and control, thereby improving initiation reliability without requiring overly complex mechanical mechanisms
2Ease of operation
If dual diode systems are used to selectively fire guns, then the system can achieve selective initiation, but the device complexity increases due to specialized control requirements
Solution Approach 1:
The switch device is designed to be universally compatible with conventional shooting panels while also enabling selective initiation of specific guns in the string. The microcontroller can detect and respond to standard control signals, allowing the system to maintain compatibility with existing equipment while adding the capability for selective firing without requiring specialized control panels
Solution Approach 2:
The microcontroller acts as an intermediary between the conventional shooting panel and the switch mechanism. It receives standard control signals from the shooting panel, processes the information to determine which gun should fire, and then activates the appropriate switch. This intermediary layer enables selective initiation while maintaining compatibility with simple conventional control panels
3Manufacturing precision
If ballistic delay fuses are used to sequence gun initiation, then the system can achieve sequential firing, but the manufacturing precision is reduced leading to off-depth perforations
Solution Approach 1:
The patent replaces ballistic delay fuses with an electronic timing and detection system based on microcontrollers. This substitution eliminates the reliance on precise mechanical fuse burning rates, which are sensitive to manufacturing variations and environmental conditions. The electronic system provides more accurate and consistent timing control, thereby improving perforation depth accuracy without requiring overly complex mechanical mechanisms
Solution Approach 2:
The switch device incorporates detection circuitry that monitors the state of other guns in the string and uses this feedback to determine when to activate. The microcontroller continuously checks circuit conditions and only activates the switch when it detects that it is the last un-fired gun, ensuring precise timing and depth control without requiring complex pre-programmed delay mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables reliable and efficient initiation of perforating guns in a string, reducing the risk of off-depth perforations and failure rates, while allowing for bypass of misfired guns and operation with conventional equipment, thereby improving the efficiency and reliability of hydraulic fracturing operations in horizontal wells.
Implementation Method 1
The microcontroller is configured for direct operative connection to a shooting panel and to other self-selecting switch devices
Implementation Method 2
The logic circuit is configured to selectively direct electrical current to the microcontroller or to the first switch
Implementation Method 3
The first switch is operative to electrically connect a shooting panel to a detonator
Implementation Method 4
Upon activating the detonator, a detonation wave passes along the detonating cord that sequentially detonates each shaped charge within the perforating gun
Data Source
AI summary
Self-selecting switch devices, perforating gun systems including the devices, and methods of using the gun systems are provided herein. A self-selecting switch device includes a microcontroller, a logic circuit, and a first switch. The microcontroller is configured for direct operative connection to a shooting panel and to other self-selecting switch devices, wherein the microcontroller is programmed to detect a presence of other self-selecting switch devices that are operatively connected thereto. The first switch is operative to electrically connect a shooting panel to a detonator. The first switch is under operational control of the microcontroller. The logic circuit is in electrical communication with the microcontroller and the first switch. The logic circuit is configured to selectively direct electrical current to the microcontroller or to the first switch.