`
`a2) United States Patent
`US 8,689,868 B2
`(0) Patent No.:
`Apr. 8, 2014
`(45) Date of Patent:
`Lercheet al.
`
`(54)
`
`(75)
`
`TRACTOR COMMUNICATION/CONTROL
`AND SELECT FIRE PERFORATING SWITCH
`SIMULATIONS
`
`Inventors: Nolan C. Lerche, Stafford, TX (US);
`James E. Brooks, Manvel, TX (US);
`Jesper Oluf Larsen, Vallensbaek Strand
`(DK); Brian Thomsen, Frederikssund
`(DK); Kasper Juul Larsen, Valby (DK)
`
`(73)
`
`Assignee: Hunting Titan, Inc., Pampa, TX (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 613 days.
`
`(21)
`
`Appl. No.:
`
`12/451,913
`
`(22)
`
`PCTFiled:
`
`Jan. 7, 2008
`
`(86)
`
`(87)
`
`(65)
`
`PCT No.:
`
`PCT/US2008/000200
`
`§ 371 (©),
`(2), (4) Date: May 3, 2010
`
`PCT Pub. No.: WO2008/100362
`
`PCT Pub. Date: Aug. 21, 2008
`
`Prior Publication Data
`
`US 2010/0286800 Al
`
`Nov. 11, 2010
`
`Related U.S. Application Data
`
`(60)
`
`Provisional application No. 60/879,169, filed on Jan.
`6, 2007.
`
`(51)
`
`Int. Cl.
`
`E21B 47/09
`E21B 47/024
`E21B 44/00
`U.S. Cl.
`
`(52)
`
`(2012.01)
`(2006.01)
`(2006.01)
`
`CPC veeceeceeeeeen E21B 47/024 (2013.01); E21B 44/00
`(2013.01)
`USPC eeeeese 166/255.1; 166/255.2; 166/66; 175/24;
`175/45
`
`(58) Field of Classification Search
`USPC we 166/255.1, 255.2, 251.1, 66; 175/4.51,
`175/24, 45; 340/853.3, 853.2, 854.9
`See application file for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`4,208,966 A
`4,986,183 A
`
`6/1980 Hart
`1/1991 Jacob
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`EP
`
`2106494
`2229503 Bl
`
`9/2011
`5/2012
`
`(Continued)
`OTHER PUBLICATIONS
`
`Office Action of Canada Patent Application No. 2,708,007, dated.
`Apr. 11, 2012, 4 pages.
`
`(Continued)
`
`Primary Examiner — Cathleen Hutchins
`(74) Attorney, Agent, or Firm — Jason A. Saunders; Arnold,
`Knobloch & Saunders, L.L.P.
`
`(57)
`
`ABSTRACT
`
`Apparatus and methods for controlling and communicating
`with one or more tools in a downhole tool string including a
`tractor, an auxiliary tractor tool, a logging tool, a safety sub,
`arelease mechanism,a unit containing sensors for monitoring
`downhole conditions, a setting tool, and a perforating gun.
`Control and communication are accomplished by sending
`signals from the surface to control switches in the control
`units on the tool, with redundant switches for safety, to state
`machinesin the respective control units, each state machine
`returning a signal verifying switch status to the surface. The
`state machine need not return a signal including a unique
`identifier.
`
`24 Claims, 18 Drawing Sheets
`
` wi.
`
`
`Traetor
`Power Unit
`
`Collector
`
`
`
`
`
`
`
`
`__|
`
`°**
`
`22
`
`
`
`
`
`
`
`
`
`
`
`
`
`Tractor
`ccL
`Safety
`Sensors
`PerfGun
`Sub
`Release
`Device
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 001
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 001
`
`
`
`US 8,689,868 B2
`Page 2
`
`(56)
`
`References Cited
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`2002/0062991 Al
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`9/2005 Farrant
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`5/2009 Bell
`5/2009 Bell
`4/2010 Bell
`5/2002 Farrant
`6/2004 Lerche
`3/2005 Lerche
`6/2006 Teowee
`
`European Search Report dated Mar. 11, 2011, EPO Application No.
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`European Examination Report of European Application No.
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`11075204.5, dated Jul. 3, 11 pages.
`European Search Report dated Jan. 9, 2012, European Application
`No. 11075204.5, 4 pages.
`European Search Report dated Jan. 9, 2012, European Application
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`2,708,007, dated Oct. 10, 2012, 25 pages.
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`pages.
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`File history of European Patent Application No. 11075204.5, 71
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`2402555 Bl
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`GB
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`WO
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`WO
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`Jun. 4, 2010, 56 pages.
`File history of European National Phase Application No. 08754055.
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`File history of European National Phase Application No. 10075761.
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`File history of Canadian National Phase Application No. 2,708,183,
`filed Jun. 4, 2010, 77 pages.
`File history of European Patent Application No. 09741043.5, filed.
`Aug. 5, 2009, issued. May 9, 2012, EP 2229503 292 pages.
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`
`Co-pending U.S. Appl. No. 12/221,611, filed Aug. 5, 2008, Lerche et
`al.
`Co-pending U.S. Appl. No. 12/934,701, filed Nov. 3, 2010, Lerche et
`al.
`International Search Report of PCT/US08/00200dated Feb. 2, 2009,
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`US09/04477, dated Mar. 11, 2010, 8 pages.
`File history of Canadian National Phase Application 2,708,007, filed
`Jun. 4, 2010, 66 pages.
`File history of European National Phase Application No.
`EP08754055.5, filed Aug. 6, 2009, 54 pages.
`File history of Canadian National Phase Application based on PCT/
`US09/04477, filed Jun. 4, 2010, 67 pages.
`File history of European National Phase Application No.
`EP09741043.5, filed Jul. 8, 2010, 61 pages.
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`Aug. 30, 2011, 63 pages.
`File history of European Patent Application No. 11075204.5, filed
`Sep. 1, 2011, 62 pages.
`
`FOREIGN PATENT DOCUMENTS
`
`OTHER PUBLICATIONS
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 002
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 002
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 1 of 18
`
`US 8,689,868 B2
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`Ex. 1023
`Pg. 003
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 003
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`U.S. Patent
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`Apr. 8, 2014
`
`Sheet 2 of 18
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`US 8,689,868 B2
`
`32
`To Wireline
`
`
`WIL
`
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`S54
`Switch
`
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`
`SurfaceComputer
`Safety Key
`
`
`Comprised Of:
`
`
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` Rx/Tx
`
`Per-Check Software
`
`Logging Software
`
`
`PerffTractor
`Perf Software
`
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`Switch
`Tractor Software
`
`
`Uplink
`
`Detect
`
`
`
`
`Tractor
`Power
`Control
`
`
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`WirelineArmor
`
`b
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 004
`
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`
`
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`
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 004
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 3 of 18
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`US 8,689,868 B2
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`Ex. 1023
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 4 of 18
`
`US 8,689,868 B2
`
`To Tractor IN
`
`
`
`Wireless
`
`Downlink
`Rx/Tx
`
`Driver
`
`
`
`
`Uplink
`Detect
`
`
`
`
`
`Current
`Limit
`
`64
`
`Figure 4
`
`oo,
`
`
`
`Surface
`
`Applies W/L Power
`
`Transmit: State "0"
`
` Top Switch
`
`
`Verify Message
` Turn W/L
`If OK
`
`
`Power OFF
`Uplink:
`
`Switch Status
`State Machine Status
`
`
`If NOT OK
`Surface
`
`
`Verify:
`Uplink Bad Message Status
`
`
`
`MessageValidity
`
`
`State Machine Status
`IF OK
`
`
`Transmit W/L ON Cmd
`
`Top Switch
`
`1F NOT OKor NO Message
`
`Verify Message
`
`Restart
`if OK
`
`
`Advance State Machine
`
`Turn W/L Switch ON
`Uplink Switch Status
`Go into hibernation
`If NOT OK
`
`Uplink Bad Message Status
`
`
` Surface
`
`Verify:
`
`
`Message Validity
`
`
`State Machine Status
`
`
`IF OK
`Transmit: State “0"
`
`IF NOT OKor NO Message
`
`Restart
`Continue to End
`
`of String
`
`Figure 5
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 006
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 006
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 5 of 18
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`US 8,689,868 B2
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`U.S. Patent
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`Apr. 8, 2014
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`Ex. 1023
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 008
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`U.S. Patent
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`Apr.8, 2014
`
`Sheet 7 of 18
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`US 8,689,868 B2
`
`Tractor Power
`
`
`;
`Micro
`Power |Ycc
`
`Supply
`
`
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`Downlink,|
`
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`Figure 9B
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 009
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 009
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`U.S. Patent
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`Apr.8, 2014
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`US 8,689,868 B2
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`U.S. Patent
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`Apr. 8, 2014
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`US 8,689,868 B2
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`U.S. Patent
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`Apr. 8, 2014
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`Sheet 10 of 18
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`US 8,689,868 B2
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`Ex. 1023
`Pg. 012
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 012
`
`
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`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 11 of 18
`
`US 8,689,868 B2
`
`W/L Out
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`Deto (+)
`
`Deta (-)
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`
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`
`Figure 15
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 013
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 013
`
`
`
`U.S. Patent
`
`Apr.8, 2014
`
`Sheet 12 of 18
`
`US 8,689,868 B2
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 014
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 014
`
`
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 13 of 18
`
`US 8,689,868 B2
`
`Event
`
`
` Power-Up
` State 0
`Invalid
`RESET
`Wait for Downlink Message
`
` Receive
`
`Message #1
`
`
`Receive Invalid
`
`
`State 1
`
`
`Message
` Uplink Invalid
`
`
`
`Validate Message #1
`Status Message
`
`
`Receive Valid
`
`Message
`
`
` State 2
`Uplink Valid Message Status
`
`Wait for Downlink Message
`
` Receive
`
`Message #2
`
`Receive Invalid
`
`
`
`State 3
`
`NO CmdAction
`Message
`
`
`Validate Message
`
`
`Decode W/L ON or ARM ON
`Uplink Invalid
`
`
`
`Status Message
`
`
` Valid W/L ON
` Valid ARM ON
`
`Message
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`
`
` State 4
`
`Turn ARM Switch ON
`
`Turn WIL Switch ON
`
`
`Uplink Valid Message Status
`Uplink Valid Status Message
`
`
`
`Go Into Hibernation
`Wait for Downlink Message
`
`
`
`
` Receive
`Message #3
`
`Receive Invalid
`State 6
`
`
`
`
`NO CmdAction
`Message
`Validate Message
`
`
`
`
`Decode FIRE Cmd
`Uplink Invalid
`
`
`Status Message
`
`
`Valid FIRE ON
`
`Message
`
`State 7
`
` Receive Firing
`
`Turn FIRE Switch ON
`Uplink Valid Status Message
`
`Wait for Firing Voltage
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 015
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 015
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 14 of 18
`
`US 8,689,868 B2
`
`
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 016
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 016
`
`
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`
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`
`U.S. Patent
`
`Apr.8, 2014
`
`Sheet 15 of 18
`
`US 8,689,868 B2
`
`
`
`
`
`
`
`{Sensor 1
`Sensor 2
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`
`
`
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`
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`
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`Ignitor Setting
`Tool
`
`Figure 19A
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` Fi
`
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`[|tractor/Log|> | Positive |Negative
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`
`
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`Tractor Motor/Electronics
`Tool
`Tool
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`
`
`
`Figure 19C
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 017
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 017
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 16 of 18
`
`US 8,689,868 B2
`
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 018
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 018
`
`
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 17 of 18
`
`US 8,689,868 B2
`
`
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 019
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 019
`
`
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`U.S. Patent
`
`Apr.8, 2014
`
`Sheet 18 of 18
`
`US 8,689,868 B2
`
`Power-Up
`
`State |
`Validate Message #1
`Verify State "0"
`__—
`Verify CRC
`Verify Message Length
`
`State 3
`Uplink Valid Message Status
`State Position "3"
`Decoded Cmd
`All Status
`Embeded address(if used)
`———~ CRC
`Wait for Downlink Measage
`
`__
`
`State 4
`.
`Validate Message #2
`Verify State "3"
`“~~~ Compare Cmd to Previous Cmd
`Verify CRC
`Verify Message Length
`
`
`
` State 0
`
`RESET
`
`Wait for Downlink Message
`
` Receive
`
`Message #1
`
`
`
`Invalid
`
`
`
`
`. State 1
`Message
`
`alidate Message #1
`
`
`7
`
`
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`Message
`
`
`State 2
`
`
`Decode Command Illegal Cmd
`
`
`
`
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`
`
`State 3
`
`Uplink Valid Message Status
`Wait for Downlink Message
`
` Receive
`
`Message #2
`
`
`
`State 6
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`
`
`
`
`.
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`
`
`
`
`alidate Message #2|
`Uplink Invalid
`
`
`Status Message
`
`
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`
`Message
`
`
`
`
` Process Command
`Uplink Status
`
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`
`
`
`Event Invalid
`Must Power Down
`
`Power
`Down
`
`Exit
`
`.
`
`State 5
`Process Command
`Uplink Status
`ae State Position "5"
`Switch Status
`Embeded address(if used)
`CRC
`Enter Sleep Mode
`Maintain logic state
`Do not listen to anyting
`
`Figure 21
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 020
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 020
`
`
`
`US 8,689,868 B2
`
`1
`TRACTOR COMMUNICATION/CONTROL
`AND SELECT FIRE PERFORATING SWITCH
`SIMULATIONS
`
`2
`1500 VDC or 1000 VAC. Tractors normally have an internal
`design that prevents tractor power from being transmitted
`below the tractor, but sometimes the circuitry fails or does not
`workproperly, allowing induced voltage or direct voltage to
`pass throughthetractor into the tool string below, which can
`include perforating gunsor logging tools. To protect the tool
`string, one or more special safety subs are located betweenit
`and the tractor. Some of the subs use electrical/mechanical
`relays to block accidental tractor power. Others use electronic
`switches that are commandedto turn off and on using com-
`munication messages from the surface that contain a unique
`address.
`
`me 0
`
`This application claims the benefit of U.S. Provisional
`Application No. 60/879,169, filed Jan. 6, 2007, which related
`patent application is hereby incorporatedin its entirety by this
`specific reference thereto.
`Perforating guns are used in operations to complete an oil
`or gas well by creating a series of tunnels through the casing
`into the formation, allowing hydrocarbons to flow into the
`wellbore. Such operations can involve multiple guns that
`Morerecently, the American Petroleum Institute has issued
`create separate perforations in multiple producing zones
`a recommendedpractice for safe tractor operations, RP 67,
`where each gun is fired separately. Operations can also
`involve single or multiple guns in conjunction with setting a 15 whichincludes arecommendationthatthe tractor be designed
`plug. The gunsare typically conveyed by wireline, tubing or
`so that it blocks unwanted voltage from passing through and
`downholetractors.
`that the design is free of any single point failure. In addition,
`Switchesare typically coupled to each detonatoror igniter
`there must be an independent, certified blocking device
`in a string of guns to determine the sequence offiring. One
`between the tractor and any perforating gun to prevent
`simple type of switch uses a diode that allows two guns (ora 20 unwanted power from being applied to a gun.
`gun and a plug)to befired, one with positive voltage and the
`It is, therefore, an object ofthe present invention to provide
`other with negative voltage. Percussion switches are typically
`a command and response system featuring fast bidirectional
`used to selectively fire three or more guns. Percussion
`communication while allowing a large number of guns to be
`switches are mechanical devices that use the force of the
`fired selectively. The system requires communication
`detonation of one gun to connectelectrically to the next one, 25 through a cable and can include communications with a
`starting with the bottom gun and workingup. The devicesalso
`downhole tractor and safety sub. Two embodimentsare pro-
`disconnect from the gun just fired, preventing the wireline
`vided, both using a state machine as part of the electrical
`from shorting out electrically. One problem with percussion
`switch to commandandidentify status within the switch. In
`switches is that if any one switch in the gun string fails to
`one, the gun position before firing is uniquely identified by
`actuate, the firing sequence cannot continue, and the gun 30 keeping track of the sequenceofstates. In the other, correct
`string has to be pulled out of the wellbore, redressed and run
`gun position is established by state and an uplink of a unique
`again.
`identifier. Unlike bidirectional communication electronic
`More recently, electronic switches have been used in
`switches, a returned downlink of the identifier is not neces-
`select-fire guns. Unlike the percussion actuated mechanical
`sary.
`switches, selective firing of guns can continue in the eventof 35
`Another object of the present invention is to provide a
`a misfired gun or a gun that cannot be fired because it is
`system that prevents tractor power from migrating past the
`flooded with wellbore fluid. One commercial switch of this
`tractor. Elements of this design are employed in a separate
`type has downlink communication but is limited in the num-
`safety sub that acts as a further safety bather to block
`ber of individual gunsthat can be fired in one run. As with the
`unwanted powerto the toolstring.
`percussion switches, the system relies on detecting changesin 40
`Other objects of the present invention, and many advan-
`current at the surface to identify gun position, which may not
`tages, will be clear to those skilled in the art from the descrip-
`be a reliable method to identify gun position in a changing
`tion of the several embodiment(s) of the invention and the to
`environment.
`drawings appended hereto. Those skilled in the art will also
`Anothertype of electronic switch has both downlink and
`recognize that the embodiment(s) described herein are only
`uplink communication, is not as limited in total number of 45 examples of specific embodiment(s), set out for the purpose
`guns that can befired in a run, but is somewhatslow tofire
`of describing the making and using of the present invention.
`because of the long bidirectional bit sequence required for
`The present invention provides a system for communicat-
`communication. Both downlink and uplink communications
`ing bi-directionally with a tractor that includes means for
`use a unique address associated with each switch to identify
`connecting and disconnecting electrical power below the
`correct gun position prior to firing.
`50 tractor. The system also allows bidirectional communication
`A common problem in operating downhole devices is
`to sensors contained in the tractor for monitoring certain
`keeping unwanted powerfrom causing catastrophic actions.
`operational functions. The communication and uplink data
`Some examples include a perforating gun receiving voltage
`transmission can occur with tractor powereither off or on. A
`that accidentally fires the gun downhole, a setting tool being
`separate safety sub uses common elements of the bidirec-
`activated prematurely, a release s device suddenly deploying 55 tional communication and switching to block unwantedvolt-
`and high voltage destroying electronics in a well logging tool
`age and to pass allowable voltage. In addition, methods are
`because its power rating is exceeded. A solution is to stop
`disclosed for disconnecting a shorted wireline below the trac-
`unwanted powerby inserting a blocking mechanism between
`tor or below the safety sub.
`the power supply and the downhole device that is to be pro-
`Also provided is a system for bi-directional communica-
`tected. In a standard perforating job, the power to log andto 60 tion with other devices such as selectively fired perforating
`detonate the perforating gun is located at the surface. Power
`guns, setting tool, release devices and downhole sensors.
`can also be generated downhole using batteries. Recently,
`According to described embodiments, the invention features
`there have been detonator designs that incorporate electronics
`asystem to select and fire specific guns ina perforatingstring.
`to block unwanted powerfrom firing a gun.
`In one embodiment each switch unit is interrogated and
`The high voltage necessary to power a downhole tractor 65
`returns a unique address thatis retrieved under system control
`presents particular problems in protecting the tool string it
`from the surface. Each location within the gunstring 1s iden-
`
`conveys. The surface voltages poweringatractor are typically tified with a particular address.
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 021
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 021
`
`
`
`US 8,689,868 B2
`
`3
`invention provides an
`the present
`In another aspect,
`embodiment in which every switch unit is identical without
`an identifying address. Each switch unit’s sequential position
`in the gun string is identified by keeping proper track of the
`numberof surface commands along with the uplink status
`from an embeddedstate machine. This predetermined chain
`of events provides surface information for determining the
`unique location of each switch unit in a given gun string.
`These enhancements allow for faster communication,initial-
`ization and firing time. As an addedfeature, all switches are
`exactly the same with no unique embeddedaddress to pro-
`gram and manage.
`Also provided is a method for controlling one or more
`devices on a tool string in a wellbore with a surface computer
`and a surface controller comprising the steps of sending a
`signal down a cable extending into the wellbore to one or
`more control units located on the devices in the tool string,
`each said control unit comprising a state machinefor identi-
`fyingthe status ofeach said control unit, processing the signal
`with the state machine, controlling the position of one or more
`switches located on the device in the toolstring whenthe state
`machineforthat device processes a valid signal, and returning
`a signal validating switch action to the surface computer.
`In another aspect, a method of switching wireline voltage
`between a tractor motoror the tractor output in a downhole
`tool string including a tractor is provided. The method com-
`prises the steps of sending a signal to a control unit on the
`tractor from the surface, processing the signal with a state
`machine on boardthe tractor for controlling the position of
`one or more switches located in one or more circuits connect-
`
`ing the wireline to either the tractor motoror a through wire
`that connects to the tool string; and returning a signal validat-
`ing switch actionto the surface. In another aspect, amethod of
`switching between a safe modefor tractoring and a perforat-
`ing mode for perforating in a tool string including a tractor
`and a perforating gun that has been lowered into a well on a
`wireline is provided. The method comprisesthesteps of send-
`ing a signal to a control unit on the tractor from the surface,
`processing the signal with a state machine for controlling the
`position of one or more switches located in one or more
`circuits for connecting the wireline to either the tractor motor
`or a through wire connecting to the perforating gun, and
`returning a signal validating switch actionto the surface.
`Also provided is an explosive initiator that is integrated
`with a control unit comprising means for receiving a signal
`from a cable to which the explosive initiator is electrically
`connected, a microcontroller including a state machine for
`validating a signal from the signal receiving means, a switch
`responsive to an output from the microcontroller when a
`signal is validated by the state machine; and an explosive
`initiator that is connected to the switch.
`In yet another aspect, the present invention provides an
`apparatus for checking the function of one or more downhole
`tools before lowering the tools into a w