Solid Signal Puck for Perforating Gun Electrical Connection

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Solution Overview

Problem

Conventional systems for connecting perforating guns in a tool string face challenges in reliably conveying electrical signals and power while withstanding explosive forces and pressure pulses, with existing tandem subs being heavy and prone to damage from downhole conditions.

Innovation Solution

A system utilizing a solid signal puck that forms a pressure-resistant barrier and electrical connection between perforating guns, ensuring reliable electrical communication and protection from fluid intrusion, with a design that includes a large outer diameter to handle pressure pulses and a conductive pathway insulated from the gun housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional tandem subs with screw threads are used to connect perforating guns, then mechanical connection is achieved, but the electrical connection reliability deteriorates under explosive forces and pressure pulses

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddamage from explosive forces and pressure pulses

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a pressure bulkhead as an intermediary component between adjacent perforating guns. This bulkhead acts as a mediator that transmits electrical signals while providing mechanical protection against explosive forces and pressure pulses. The bulkhead includes a throughbore for electrical connection and pressure seals to protect the interior void space, thereby resolving the contradiction between maintaining electrical connection reliability and protecting against harmful explosive forces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stress or pressure

If the interior of perforating guns is filled with liquid, then pressure resistance is improved, but electrical component damage risk increases

Engineering Contradiction:

Improvepressure resistanceVSAvoidelectrical component damage

Core Design Contradiction:

Stress or pressureVSObject-affected harmful factors

Solution Approach 1:

The patent divides the perforating gun system into separate pressure zones using pressure bulkheads. Each gun maintains its own dry interior void space while the annular space between adjacent guns can be filled with liquid for pressure resistance. This segmentation allows electrical components to remain protected in dry zones while the system as a gain benefits from liquid-filled pressure-resistant zones.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If small diameter pressure bulkheads are used, then blast pulse magnitude is reduced, but electrical connection reliability worsens

Engineering Contradiction:

Improveblast pulse magnitudeVSAvoidelectrical signal conduction

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent nests the electrical connection components within the pressure bulkhead structure. The throughbore containing electrical connectors is nested inside the larger pressure bulkhead body, allowing the bulkhead to provide mechanical protection and reduce blast pulse magnitude while the nested electrical connection pathway maintains reliable signal conduction through the protected interior void space.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

The system effectively connects and protects perforating guns, enhancing the reliability of electrical communication and mechanical integrity, reducing the risk of damage from explosive forces and fluid intrusion, thereby improving the efficiency and safety of hydrocarbon production operations.

Implementation Method 1

the solid signal puck is in direct physical contact with both the first electrical connector and with the second electrical connector for conducting at least one of electrical signals and electrical power between the first electrical connector and the second electrical connector

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

the puck forms a pressure resistant barrier between the gun and the tool

Methodology Applied

Scientific EffectPressure resistance:

Implementation Method 3

the solid signal puck not only forms a pressure resistant barrier for the perforating guns, but also seals fluids from entering either of the interior void spaces at the end to end connection

Methodology Applied

Scientific EffectFluid sealing:

Data Source

PatentUS12078018B2Solid signal puck for wellbore perforating gun

Publication Date: 2024.09.03 G&H DIVERSIFIED MFG LP

AI summary

A system for connecting a perforating gun to at least one other component in a perforating tool string includes a perforating gun that includes a gun housing and a charge carrier received within the gun housing wherein the charge carrier includes a first electrical connector, a tool connected end-to-end with the perforating gun where the tool includes an outer sleeve and a second electrical connector, a solid signal puck arranged with the perforating gun and the tool where the puck forms a pressure resistant barrier between the gun and the tool and wherein the solid signal puck includes a first endface oriented and a second endface and an outer periphery between the endfaces, and wherein the largest outer diameter of the outer periphery is at least 40% of the length between the first endface and the second endface of the puck.