Universal Initiator for Perforating Guns

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Solution Overview

Problem

Current downhole perforating systems face challenges in safety and reliability due to the complex and error-prone nature of assembling and handling explosive devices, which can lead to human error and unintended detonation.

Innovation Solution

A universal initiator for perforating guns featuring a multi-piece housing with a pre-installed detonator and printed wiring assembly (PWA) that includes simplified connectors and safety mechanisms such as microprocessors and ferrite components to prevent unintentional detonation, allowing for quick and easy assembly and reducing human error.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If safety mechanisms and complex assembly procedures are added to prevent premature ignition, then safety and reliability improve, but device complexity and risk of human error increase

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The initiator is divided into separate modules: a detonator module containing the explosive element and a wiring module containing the electrical connections. These modules can be assembled separately and then combined, allowing safety checks to be performed on each module independently before final assembly, thereby improving safety without requiring the entire system to be overly complex

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The detonator is pre-installed and pre-positioned within the initiator housing during manufacturing, with safety features such as insulation barriers and positioning mechanisms already in place. This preliminary preparation ensures that when the initiator is assembled at the well site, the critical safety elements are already configured correctly, reducing the complexity of on-site assembly while maintaining high safety standards

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If manual handling and assembly of perforating guns are simplified, then ease of operation improves, but risk of human error and handling issues increases

Engineering Contradiction:

Improveease of assemblyVSAvoidhuman error risk

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The initiator is designed as a modular unit with distinct sections for the detonator, wiring harness, and housing. Each module has standardized connection interfaces that guide proper assembly through physical alignment features, making the assembly process intuitive and reducing the likelihood of incorrect connections while maintaining simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Traditional complex mechanical locking mechanisms and multiple fasteners are replaced with simplified connection systems such as bayonet-style connectors or snap-fit interfaces. These simplified mechanisms provide adequate mechanical and electrical connections while requiring fewer manual steps and reducing the complexity of the assembly procedure, thereby lowering human error risk

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If wiring harnesses and connectors are simplified for easier assembly, then ease of operation improves, but manufacturing precision and reliability may be compromised

Engineering Contradiction:

Improvewiring assemblyVSAvoidwiring precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The wiring system is segmented into pre-assembled sub-harnesses with connectors pre-attached and tested. Each sub-harness is manufactured and quality-checked separately, ensuring precise wiring connections are made under controlled manufacturing conditions rather than in the field. The simplified connector interfaces then make assembly easier while the pre-manufactured precision wiring maintains reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

All wiring connections, connector attachments, and electrical pathways are pre-configured and pre-tested during the manufacturing process. Quality control measures including continuity checks, insulation resistance tests, and connector mating tests are performed before the initiator leaves the factory. This preliminary preparation ensures manufacturing precision is maintained while the simplified design allows easy assembly and handling at the well site

Inventive Principle:

Principle #10Preliminary action

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 universal initiator enhances safety and reliability by simplifying the assembly process, reducing wiring mistakes, and preventing premature detonation, while maintaining ease of use across various perforating gun sizes and configurations.

Implementation Method 1

a printed wiring assembly (PWA) between the upper module and the lower module... The printed wiring assembly has a least one microprocessor that is connected to the detonator

Methodology Applied

Scientific EffectElectrical signal detection and control: Conduction (electrical)

Implementation Method 2

At least one ferrite component is mounted on the PWA to block electromagnetic interference

Methodology Applied

Scientific EffectElectromagnetic interference blocking: Magnetic Field

Data Source

PatentUS11377935B2Universal initiator and packaging

Publication Date: 2022.07.05 SCHLUMBERGER TECH CORP

AI summary

A wellbore perforating system including a multi-component universal initiator. The universal initiator is a “plug and play” initiator able to accommodate a wide range of perforating gun system.