Switch Sub Adapter Dart Sealing for Perforating Guns

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Solution Overview

Problem

Existing switch subs in perforating and fracturing operations suffer from damage to internal electronics due to detonation debris, wellbore fluid, and pressure waves, requiring costly replacement and slowing down the process.

Innovation Solution

A switch sub adapter with a dart mechanism that seals both ends of the internal chamber, preventing pressure waves from propagating and protecting the electronics, and a dart puck that seals the conduit to prevent damage from upstream detonations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the switch sub is used to connect perforating gun assemblies, then the electronics can control and coordinate detonation signals, but the electronics are damaged by detonation debris, wellbore fluid, and pressure waves

Engineering Contradiction:

Improveswitch sub functionalityVSAvoidelectronics durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The switch sub is divided into separate functional zones: an upstream sealed chamber protecting electronics from upstream detonation debris, a downstream sealed chamber protecting electronics from downstream detonation debris, and a central conduit area. This segmentation allows each zone to be independently protected while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A dart mechanism acts as an intermediary sealing element between the upstream and downstream chambers. The dart can be positioned to seal off the conduit from upstream pressure waves while allowing downstream pressure waves to pass through, thereby protecting electronics from upstream damage while maintaining downstream communication.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the switch sub is exposed to detonation debris and pressure waves, then the perforating operations can proceed, but the electronics inside the switch sub are damaged and require replacement

Engineering Contradiction:

Improveoperational speedVSAvoidelectronics replacement

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The switch sub is pre-assembled with sealed chambers and dart mechanisms before being lowered into the wellbore. The sealing structures are already in place to protect the electronics from the moment the first detonation occurs, eliminating the need for post-detonation repairs or replacements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sealed chambers and dart mechanisms serve as protective barriers that cushion the electronics from the full force of detonation debris and pressure waves before the damage can occur. This beforehand protection allows the switch sub to withstand multiple detonation cycles without electronic failure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If the switch sub internal chamber is not sealed, then the structure remains simple, but pressure waves from detonation propagate through and damage the electronics

Engineering Contradiction:

Improvechamber structureVSAvoidpressure wave damage

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The sealing mechanism uses a movable dart that can dynamically adjust its position based on pressure differential. The dart moves to seal the conduit when upstream pressure waves are detected and can be displaced when downstream pressure waves need to pass through, providing adaptive protection without requiring complex rigid sealing structures.

Inventive Principle:

Principle #15Dynamics

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

Enables the reuse of switch subs and their electronics by effectively sealing the internal chamber from detonation-related damage, reducing operational costs and increasing efficiency.

Implementation Method 1

a dart located inside the dart puck and configured to seal the conduit so that a pressure wave generated by the upstream perforating gun assembly does not propagate into the chamber to damage the electrical device

Methodology Applied

Scientific EffectPressure wave blocking:

Implementation Method 2

a seal mechanism that prevents detonation debris and wellbore fluid from entering the internal chamber

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11208873B2Switch sub with two way sealing features and method

Publication Date: 2021.12.28 BAKKEN BALL RETRIEVAL LLC

AI summary

A switch sub adapter configured to connect a switch sub to a perforating gun assembly. The switch sub adapter includes a tubular body having first threads that connect to the switch sub and second threads that connect to the perforating gun assembly; a first internal chamber formed at a first end of the adapter; a second internal chamber formed at a second end of the adapter; a conduit connecting the first internal chamber to the second internal chamber; and a dart having a tip located in the conduit and a base part located in the second internal chamber. The dart is formed from a compliant material that deforms in response to pressure resulting from detonation of charges associated with the perforating gun.