US008576090B2
`
`US 8,576,090 B2
`(10) Patent No.:
`a2) United States Patent
`Lercheetal.
`(45) Date of Patent:
`Nov. 5, 2013
`
`
`(54) APPARATUS AND METHODS FOR
`CONTROLLING AND COMMUNICATING
`WITH DOWNWHOLEDEVICES
`
`(75)
`
`Inventors: Nolan C. Lerche, Stafford, TX (US);
`James E. Brooks, Manvel, TX (US)
`.
`,
`.
`(73) Assignee: Hunting Titan, Ltd., Pampa, TX (US)
`
`6,959,765 B2
`7,081,831 B2*
`7,347,278 B2
`7530397 B2
`7,536,942 B2
`7,698,982 B2
`2002/0062991 Al
`
`11/2005 Bell
`7/2006 Dodge oes 340/855.4
`3/2008 Lercheet al.
`5/2009 Bell
`5/2009 Bell
`4/2010 Bell
`5/2002 Farrant
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`(*) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 139 days.
`
`CA
`EP
`
`(21) Appl. No.: 12/221,611
`
`(22)
`
`Filed:
`
`Aug. 5, 2008
`
`(65)
`
`Prior Publication Data
`
`US 2011/0090091 Al
`
`Apr. 21, 2011
`
`2/2010
`2708183 Al
`$/2012
`2229503 Bl
`(Continued)
`OTHER PUBLICATIONS
`
`International Preliminary Report on Patentability, PCT/US09/04477,
`dated Feb. 17, 2011, 9 pages.
`
`(Continued)
`
`Primary Examiner — Benjamin Fiorello
`Related U.S. Application Data
`(74) Attorney, Agent, or Firm — Jason A. Saunders; Arnold,
`(63) Continuation-in-part
`of
`application
`Knobloch & Saunders, L.L.P
`PCT/US2008/000200,filed on Jan. 7, 2008.
`(57)
`ABSTRACT
`Int.Cl.
`Apparatus and methods for controlling and communicating
`E21B 43/1185
`with one or more tools in a downhole tool string including a
`(52) U.S. CL.
`USPC veceecceccecee 340/853.2; 340/855.3; 340/855.7;_tractor, an auxiliary tractor tool, a logging tool, a safety sub,
`166/66
`arelease mechanism,a unit containing sensors for monitoring
`downhole conditions, a setting tool, and a perforating gun.
`Also provided are apparatus and methodsfor controlling and
`communicating with one or more perforating guns, release
`devices, and explosive devices in a string to be lowered into a
`wellbore. Control and communication are accomplished by
`sending signals from the surface to control switches in the
`control units on the tool, with redundant switchesfor safety,
`to state machines in the respective control units, each state
`machine returning a signal verifying switch status to the
`surface. Control and powerfunctions are accomplished with
`voltage of different polarities for safety.
`
`No.
`
`(51)
`
`(2006.01)
`
`(58) Field of Classification Search
`USPC .......... 340/853.2, $54.1, 855.3, 855.5, 855.7;
`166/66
`See applicationfile for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`foesies ‘
`6.283.227 BL
`6,604,584 B2
`6,938,689 B2
`
`Wloot me
`9/2001. Lercheetal.
`8/2003 Lerche
`9/2005 Farrant
`
`12 Claims, 27 Drawing Sheets
`
`
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 001
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 001
`
`

`

`US 8,576,090 B2
`Page 2
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`2004/0108114 Al
`2005/0045331 Al
`2006/0130693 Al
`2011/0066378 Al
`
`6/2004 Lerche
`3/2005 Lerche
`6/2006 Teowee
`3/2011 Lercheetal.
`
`FOREIGN PATENT DOCUMENTS
`
`File history of European Divisional Patent Application No.
`10075761.6, 26 pages.
`File history of European Divisional Patent Application No.
`11075202.9, 141 pages.
`File history of European Divisional Patent Application No.
`11075204.5, 137 pages.
`Communication pursuant to Article 94(4) EPC, Application No.
`10075761.6, 4 pages.
`USS. Appl. No. 12/451,913, filed Dec. 3, 2009, Lerche etal.
`U.S. Appl. No. 12/934,701, filed Sep. 27, 2010, Lerche etal.
`2/2000
`2340157 A
`GB
`International Search Report of PCT/US08/00200dated Feb. 2, 2009,
`5/2000
`0024999 Al
`WO
`4 pages.
`
`WO 2007143759 Al—12/2007
`Written Opinion of the International Searching Authority, PCT/
`WO
`2008100362 A2
`8/2008
`US08/00200, dated Feb. 2, 2009, 6 pages.
`WO
`2010016897
`2/2010
`International Preliminary Report on Patentability, PCT/US08/00200,
`dated Jul. 7, 2009, 7 pages.
`International Search Report of PCT/US09/04477, dated Mar. 11,
`2010, 6 pages.
`Written Opinion of the International Searching Authority, PCT/
`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.
`
`OTHER PUBLICATIONS
`
`Examination Report, European Patent Application No. 09741043.5,
`dated Jan. 13, 2011, 3 pages.
`File history of European Patent Application No. 100755784, filed
`Aug. 5, 2008, 61 pages.
`European Search Report dated Oct. 18, 2011 European Patent Appli-
`cation No. 10075578 4, 8 pages.
`File history of European Patent No. 2229503, 290 pages.
`File history of European Patent Application No. 10075578.4, 180
`pages.
`Response to Communication pursuant to Rules 70(2) and 70a(2) of
`European Patent Application No. 10075578 4, 8 pages.
`File history of Canadian Patent Application No. 2,708,183, 61 pages.
`File history of Canadian Patent Application No. 2,708,007, 30 pages.
`
`* cited by examiner
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 002
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 002
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 1 of 27
`
`US 8,576,090 B2
`
`4
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`Hunting Titan, Inc.
`Ex. 1024
`Pg. 003
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 003
`
`
`
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 2 of 27
`
`US 8,576,090 B2
`
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`Hunting Titan, Inc.
`Ex. 1024
`Pg. 004
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 004
`
`
`
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 3 of 27
`
`US 8,576,090 B2
`
`NNO43d
`
`SYOSNIS
`
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`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 005
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 005
`
`
`
`

`

`U.S. Patent
`
`NIYOLOVYLOLa
`
`Nov.5, 2013
`
`Sheet 4 of 27
`
`US 8,576,090 B2
`
`
`
`
`
`
`
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`
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`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 006
`
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`
`SSTT3UIM
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 006
`
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 5 of 27
`
`US 8,576,090 B2
`
`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
`
`
` SURFACE
`IF NOT OK
`
`
`UPLINK BAD MESSAGE STATUS
`
`
`
`VERFIY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`
`IF OK
`
`
`TRANSMIT W/L ON CMD
`iF NOT OK OR NO MESSAGE
`
`RESTART
`
`TOP SWITCH
`VERIFY MESSAGE
`
`IF OK
`
`ADVANCE STATE MACHINE
`
`TURN W/L SWITCH ON
`
`UPLINK SWITCH STATUS
`
`GO INTO HIBERNATION
`
`IF NOT OK
`UPLINK BAD MESSAGE STATUS
`
`
`
`
`
`IF
`
`
`
`
`
` SURFACE
`VERIFY:
`
`
`
`
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`OK
`
`TRANSMIT: STATE “0”
`IF NOT OK OR NO MESSAGE
`
`RESTART
`
`FIG. 5
`
`CONTINUE TO END
`OF STRING
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 007
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 007
`
`

`

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`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 6 of 27
`
`US 8,576,090 B2
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`Hunting Titan, Inc.
`Ex. 1024
`Pg. 008
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 008
`
`
`
`

`

`Sheet 7 of 27
`
`US 8,576,090 B2
`
`U.S. Patent
`
`Nov.5, 2013
`
`JOONYOLOVaL
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 009
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 8 of 27
`
`US 8,576,090 B2
`
`FIG. 8
`
`
`
`OC
`
`aap
`
`
`
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`
`ccw
`
`SAFE MODE STATUS
`
`FIG. 9B
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 010
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 010
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 9 of 27
`
`US 8,576,090 B2
`
`niLA
`
`193NNOOSIO
`
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`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. O11
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 011
`
`
`

`

`U.S. Patent
`
`LOINNOOSI
`
`Nov.5, 2013
`
`Ly
`
`Sheet 10 of 27
`
`US 8,576,090 B2
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 012
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 012
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 11 of 27
`
`US 8,576,090 B2
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`Hunting Titan, Inc.
`Ex. 1024
`Pg. 013
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 013
`
`
`
`
`
`

`

`LOANNOOSIO 1LNAHS
`
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`
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`
`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 12 of 27
`
`US 8,576,090 B2
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`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 014
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 014
`
`
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 13 of 27
`
`US 8,576,090 B2
`
`
` SURFACE
`APPLY W/L POWER
`
`TRANSMIT MSG #1
`
`STATE “0”
`
`
`
`UNIT COMMAND
`
`
`ALL UNITS
`VERIFY MESSAGE
`
`
`IF NOT OK
`
`
`SURFACE
`GO TO STATE "0"—RESET
`
`VERIFY:
`IF OK
`
`
`
`ADVANCE STATE MACHINE
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`DECODE COMMAND
`IF NOT OK OR NO MESSAGE
`IF ILLEGAL
`
`
`GO TO STATE "0°—RESET
`RESTART
`
`
`IF LEGAL
`|
`IF OK
`
`TRANSMIT MSG #2
`ADVANCE STATE MACHINE
`
`
`
`
`UPLINK VALID MESSAGE
`STATUS
`
`WAIT FOR NEXT DOWNLINK
`MESSAGE
`
`TURN W/L
`POWER OFF
`
`
`
`
`
`
`
`
`
` SPECIFIC UNIT
`VERIFY MESSAGE
`IF NOT OK
`UPLINK BAD MESSAGE STATUS
`MUST POWER DOWN TO
`CONTINUE
`IF OK
`PROCESS COMMAND
`UPLINK:
`SWITCH STATUS
`STATE MACHINE STATUS
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`SURFACE
`
`
`
`VERIFY:
`
`MESSAGE VALIDITY
`
`STATE MACHINE STATUS
`
`
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`
`
`IF OK
`ACCEPT DATA
`
`
`CONTINUE TO NEXT UNIT
`
`
`FIG. 10
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 015
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 015
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 14 of 27
`
`US 8,576,090 B2
`
`POWER-UP
`
` STATE 0
`RESET
`WAIT FOR DOWNLINK MESSAGE
`
`
`
`
`
`ILLEGAL CMD
`
`STATE 2
`DECODE COMMAND
`
`LEGAL CMD
`
`
`
`UPLINE.TNVALID
`STATUS NEROLOE
`
`INVALID
`
`MESSAGE
`
`O)
`EVENT INVALID
`MUST POWER DOWN
`
`
`
`STATE 3
`UPLINK VALID MESSAGE STATUS
`WAIT FOR DOWNLINK MESSAGE
`
`RECEIVE
`MESSAGE #2
`STATE 4
`VALIDATE MESSAGE #2
`VALID
`MESSAGE
`
`STATE 5
`PROCESS COMMAND
`UPLINK STATUS
`
`ENTER SLEEP MODE
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 016
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 016
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 15 of 27
`
`US 8,576,090 B2
`
`JALVIIN|3AULISOd
`
`
`9NID901|INIDDOTSOV/MOLOVAL
`TOOLTOOLSQINOMLOITI/YOLONYOLOVALYITIOMLNOD
`
`
`
`
`
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`
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`
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`
`
`
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`
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`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 017
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 017
`
`
`
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 16 of 27
`
`US 8,576,090 B2
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 018
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 018
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 17 of 27
`
`US 8,576,090 B2
`
`
`
`FIG. 14A
`
`
`
`FIG. 15
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 019
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 019
`
`

`

`U.S. Patent
`
`(+)O13YOWNYY7/M
`
`01300150
`
`SNLVLSaHOLIMS
`
`(-)o130
`
`YINFIIIY
`
`Nov.5, 2013
`
`Sheet 18 of 27
`
`US 8,576,090 B2
`
`dblOld indV/MNI7/M Alddns
`YIMOd
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 020
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 020
`
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 19 of 27
`
`US 8,576,090 B2
`
`FIG. 16A
`
`
`
`SWITCH °2"
`
`
`
`SURFACE
`APPLIES W/L POWER
`
`
`TRANSMIT STATE “0”
`
`SWITCH "3"
`
`
`VERIFY MESSAGE
`TURN W/L
`IF OK
`
`POWER OFF
`UPLINK:
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`SURFACE
`IF NOT OK
`
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`
`
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`
`
`
`IF OK
`
` SWITCH "3°
`TRANSMIT W/L ON CMD
`
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`
`
`TURN W/L SWITCH ON
`
`UPLINK:
`SWITCH STATUS
`
`STATE MACHINE STATUS
`
`
`
`
`GO INTO HIBERNATION
`SURFACE
`IF NOT OK
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`
`MESSAGE VALIDITY
`
`
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`
`TRANSMIT STATE “oO”
`
`
`SWITCH °2°
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`RESTART
`
`IF OK
`UPLINK:
`
`
`SWITCH STATUS
`
`
`
`STATE MACHINE STATUS
`SURFACE
`IF NOT OK
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`MESSAGE VALIDITY
`
` OK
`STATE MACHINE STATUS
`IF OK
`
`TRANSMIT W/L ON CMD
`
`
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`OK
`
`(8)
`
`UPLINK BAD MESSAGE STATUS
`
`TURN W/L SWITCH ON
`UPLINK:
`SWITCH STATUS
`
`STATE MACHINE STATUS
`
`GO INTO HIBERNATION
`IF NOT OK
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 021
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 021
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 20 of 27
`
`US 8,576,090 B2
`
`A)
`
`SURFACE
`
`NOT
`
`
`
`
`
`
`
`
`
`
`
`VERIFY:
`MESSAGE VALIDITY
`
`
`STATE MACHINE STATUS
`
`
`IF OK
`TRANSMIT: STATE “0”
`
`IF NOT OK OR NO MESSAGE
` SWITCH “1”
`
`
`RESTART
`
`
`VERIFY MESSAGE
`
`IF OK
`UPLINK:
`
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`SURFACE
`
`IF NOT OK
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`
`MESSAGE VALIDITY
`
`
`STATE MACHINE STATUS
`
`
`
`IF OK
`
`TRANSMIT ARM ON CMD
`
`
`
`SWITCH °1”
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`
`RESTART
`
`IF OK
`TURN ARM SWITCH ON
`
`UPLINK:
`
`SWITCH STATUS
`
`STATE MACHINE STATUS
`
`IF NOT OK
`
`
`SURFACE
`UPLINK BAD MESSAGE STATUS
`
`
`
`VERIFY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`IF OK
`
`
`
`TRANSMIT FIRE ON CMD
`
`
`SWITCH “1”
`IF NOT OK OR NO MESSAGE
`
`
`VERIFY MESSAGE
`RESTART
`
`IF OK
`TURN FIRE SWITCH ON
`
`
`UPLINK:
`
`
`SWITCH STATUS
`
`
`
`SURFACE
`STATE MACHINE STATUS
`
`
`
`IF NOT OK
`
`
`
`UPLINK BAD MESSAGE STATUS
`
`
`
`VERIFY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`IF OK
`APPLY SHOOTING VOLTAGE
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`OK
`
`SWITCH °1”
`FIRES DETONATOR
`
`FIG. 16B
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 022
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 022
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 21 of 27
`
`US 8,576,090 B2
`
`INVALID
`;
`O
`
`POWER-UP
`
`
`
`STATE O
`RESET
`WAIT FOR DOWNLINK MESSAGE
`
`RECEIVE
`
`RECEIVE
`MESSAGE #1
`
`STATE 1
`VALIDATE MESSAGE #1
`
`
`MESSAGE
`
`UPLINK INVALID
`
`STATUS MESSAGE
`
`RECEIVE VALID
`MESSAGE
`
`
` STATE 2
`
`
`UPLINK VALID MESSAGE STATUS
`
`WAIT FOR DOWNLINK MESSAGE
`
`
`
`
`STATE 9
`NO CMD ACTION
`
`UPLINK INVALID
`
`STATUS MESSAGE
`
`
`|MESSAGE!
`
`
`
`STATE 3
`valipATE MESSAGE
`
`DECODE W/L ON OR ARM ON
`
`VALID RW ON
`
`
`
`
`
`
`STATE 4
`STATE 5
`TURN W/L SWITCH ON
`TURN ARM SWITCH ON
`
`UPLINK VALID MESSAGE STATUS
`UPLINK VALID MESSAGE STATUS
`GO INTO HIBERNATION
`WAIT FOR DOWNLINK MESSAGE
`
`
`NO CMD ACTION 10
`sae?
`
`
`
`VALIDATE MESSAGE
`UPLINK INVALID
`DECODE FIRE CMD
`
`
`STATUS MESSAGE
`
`
`VALID FIRE ON
`MESSAGE
`
`
`
`STATE 7
`RECEIVE FIRING VOLTAGE|TURN FIRE SWITCH ON
`\/
`EXIT (9
`UPLINK VALID STATUS MESSAGE
`
`WAIT FOR FIRING VOLTAGE
`
`FIG. 17
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 023
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 023
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 22 of 27
`
`US 8,576,090 B2
`
`START
`
`FIG. 18A
`
` SWITCH *3”
`
`
`
`SURFACE
`APPLIES POWER
`
`TRANSMIT STATE “0”
`
`
`
`
`VERIFY MESSAGE
`TURN W/L
`IF OK
`
`POWER OFF
`UPLINK:
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`
`SURFACE
`IF NOT OK
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`
`MESSAGE VALIDITY
`
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`TRANSMIT W/L ON CMD
`SWITCH “3”
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`RESTART
`
`IF OK
`TURN W/L SWITCH ON
`UPLINK:
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`GO INTO HIBERNATION
`
`
`
`SURFACE
`IF NOT OK
`
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
`
`MESSAGE VALIDITY
`
`STATE MACHINE STATUS
`
`IF OK
`
`
`TRANSMIT STATE “0”
`
`
`SWITCH “2”
`
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`
`RESTART
`
`IF OK
`UPLINK:
`
`SWITCH STATUS
`
`
`
`STATE MACHINE STATUS
`
`
`SURFACE
`IF NOT OK
` VERIFY:
`
`
`UPLINK BAD MESSAGE STATUS
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`
`OK|IF OK
`
`TRANSMIT W/L ON CMD
`SWITCH "2"
`IF NOT OK OR NO MESSAGE
`VERIFY MESSAGE
`RESTART
`IF OK
`TURN W/L SWITCH ON
`UPLINK:
`SWITCH STATUS
`STATE MACHINE STATUS
`GO INTO HIBERNATION
`IF NOT OK
`
`OK
`
`UPLINK BAD MESSAGE STATUS
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 024
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 024
`
`

`

`U.S. Patent
`
`Nov. 5,
`
`2013
`
`Sheet 23 of 27
`
`US 8,576,090 B2
`
`VERIFY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`IF OK
`TRANSMIT: STATE “O”
`IF NOT OK OR NO MESSAGE
`RESTART
`
` SURFACE
`
`
`
`
`
`
` SWITCH "1"
`
`VERIFY MESSAGE
`IF OK
`
`UPLINK:
`
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`
`SURFACE
`IF NOT OK
`
`
`VERIFY:
`UPLINK BAD MESSAGE STATUS
` MESSAGE VALIDITY
`
`STATE MACHINE STATUS
`IF OK
`
`
`TRANSMIT ARM ON CMD
`
`SWITCH “1”
`
`
`IF NOT OK OR NO MESSAGE
`
`
`VERIFY MESSAGE
`
`RESTART
`IF OK
`
`TURN ARM SWITCH ON
`
`UPLINK:
`
`SWITCH STATUS
`STATE MACHINE STATUS
`
`IF NOT OK
`
`
`
`SURFACE
`
`UPLINK BAD MESSAGE STATUS
`
`
`
`VERIFY:
`
`
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`TRANSMIT FIRE ON CMD
`
`SWITCH “1”
`
`IF NOT OK OR NO MESSAGE
`
`
`
`VERIFY MESSAGE
`RESTART
`
`IF OK
`TURN FIRE SWITCH ON
`
`
`UPLINK:
`
`
`SWITCH STATUS
`
`
`
`SURFACE
`STATE MACHINE STATUS
`
`VERIFY:
`IF NOT OK
`MESSAGE VALIDITY
`
`UPLINK BAD MESSAGE STATUS
`
`
`
`STATE MACHINE STATUS
`
`IF OK
`
`APPLY SHOOTING VOLTAGE
`
`
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`OK
`
`
`
`SWITCH *1”
`FIRES DETONATOR
`
`FIG. 18B
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 025
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 025
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 24 of 27
`
`US 8,576,090 B2
`
`aaaPottpqsssq
`
`|
`l
`
`||
`
`|
`|
`|
`
`SENSOR 1
`!
`SENSOR 2
`|
`SENSOR 3
`SENSOR _4 |
`
`PS
`MICRO
`
`|
`
`|
`
`|
`W/L RELEASE
`
`|
`|
`I
`
`{
`{
`|
`
`|
`|
`
`PS
`MICRO
`RX, TX
`
`OT ee ee 7
`
`PS
`
`|+—-};
`micRoO.
`|
`
`| L_R% IX|DEO IT
`!
`sw |b)
`DETO
`GUN
`|
`A]
`|
`
`|___ LEI W/L SW |
`
`| neers (ea 7
`|
`
`PS
`MICRO
`RX, 1X
`
`fhTO |! : IGNITOR
`
`SETTING TOOL
`
`FIG. 19A
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 026
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 026
`
`

`

`U.S. Patent
`
`Nov.5, 2013
`
`Sheet 25 of 27
`
`US 8,576,090 B2
`
`
`
`
`
`XL/xa
`
`
`
`YITIONLNODFO¥IUNS2EzSuPYSSTGMIM
`
`ee
`
`“N\
`
`ZiLOs13S9alLO773S%QILFS£GlLOTS g0lvolaoc20E|g0t|voel
`
`z#YOLOVeLt#YOLOVaL
`
`or[
`
`CFUaINdNOD
`XYSIMdOldv¥1
`
`YOLOVeL
`
`
`
`AlddNSY3M0d
`
`2
`
`
`
`g6l‘Oldace
`
`ver!
`
`
`(u-z)1001|TOLYAN
`95NID9075NI9907199
`
`
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 027
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 027
`
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 26 of 27
`
`US 8,576,090 B2
`
`
`
`
` SURFACE
`APPLY W/L POWER
`
`TRANSMIT MSG #1
`
`STATE “0°
`UNIT COMMAND
`
`TURN W/L
`POWER OFF
`
`
`ALL PARALLEL AND TOP
`SERIES UNITS
`
`VERIFY MESSAGE
`IF NOT OK
`
`
`SURFACE
`GO TO STATE “0”—RESET
`
`
`
`
`IF OK
`VERIFY:
`ADVANCE STATE MACHINE
`MESSAGE. VALIDITY
`
`STATE MACHINE STATUS
`DECODE COMMAND
`
`
`
`IF NOT OK OR NO MESSAGE
`IF ILLEGAL
`
`
`
`GO TO STATE "0°—RESET
`RESTART
`
`
`
`IF LEGAL
`IF OK
`
`
`
`TRANSMIT MSG #2
`
`ADVANCE STATE MACHINE
`
`
`
`UPLINK VALID MESSAGE
`STATUS
`
`WAIT FOR NEXT DOWNLINK
`MESSAGE
`
`
`
`
`
`
` SPECIFIC UNIT RESPONDS
`VERIFY MESSAGE
` SURFACE
`
`IF NOT OK
`
`UPLINK BAD MESSAGE STATUS
`VERIFY:
`
`
`MUST POWER DOWN TO
`MESSAGE VALIDITY
`
`
`CONTINUE
`ALL STATUS
`
`IF NOT OK OR NO MESSAGE
`IF O,
`
`K
`
`
`
`
`PROCESS COMMAND
`RESTART
`UPLINK: STATUS
`
`IF OK
`
`
`ACCEPT DATA
`
`
`CONTINUE
`
`FIG. 20
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 028
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 028
`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 27 of 27
`
`US 8,576,090 B2
`
` _
`STATE 0
`C)POWER-UP_|
`ppcey
`WAIT FOR DOWNLINK MESSAGE
`
`
`
`STATE 1
`
`
`VALIDATE MESSAGE f!
`VERIFY STATE “O
`VERIFY CRC
`
`VERIFY MESSAGE LENGTH
`
`
`STATE 2
`DECODE COMMAND
`
`LEGAL CMD
`
`STATE 3
`UPLINK VALID MESSAGE STATUS
`STATE POSITION “3”
`DECODED CMD
`ALL STATUS
`EMBEDDED ADDRESS
`(IF USED)
`CRC
`WAIT FOR DOWNLINK MESSAGE
`
`RECEIVE
`MESSAGE #2
`
`STATE 4
`INVALID|VALIDATE MESSAGE #2
`STATE 6
`MESSAGE
`VERIFY STATE “3
`COMPARE CMD TO
`PREVIOUS CMD
`VERIFY CMD
`VERIFY MESSAGE LENGTH
`
`STATUS MESSAGE
`
`
` UPLINK INVALID
`DO NOT LISTEN TO ANYTHING
`
`:
`C)
`EVENT INVALID
`MUST POWER DOWN
`
`FIG. 21
`
`VALID
`MESSAGE
`
`STATE 5
`PROCESS COMMAND
`UPLINK STATUS
`STATE POSITION "5"
`SWITCH STATUS
`EMBEDDED ADDRESS
`eon
`ENTER SLEEP MODE
`MAINTAIN LOGIC STATE
`
`POWER
`DOWN
`0) EXIT
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 029
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 029
`
`

`

`US 8,576,090 B2
`
`1
`APPARATUS AND METHODS FOR
`CONTROLLING AND COMMUNICATING
`WITH DOWNWHOLE DEVICES
`
`RELATED APPLICATIONS
`
`This application is a continuation-in-part of International
`Application No. PCTIUS2008/00200, TRACTOR COM-
`MUNICATION/CONTROL AND SELECT FIRE PERFO-
`RATING SWITCH,filed Jan. 7, 2008, which related patent
`application is hereby incorporatedin its entirety by this spe-
`cific reference thereto.
`
`BACKGROUND OF THE INVENTION
`
`Perforating guns are used to complete an oil or gas well by
`creating a series of tunnels through the casing into the forma-
`tion, allowing hydrocarbonsto flow into the wellbore. Such
`operations can involve multiple guns that create separate
`perforations in multiple producing zones where, each gun is
`fired separately. Operations can also involve single or mul-
`tiple guns in conjunction with setting a plug. The guns are
`typically conveyedto the producing zone(s) by wireline, tub-
`ing or downholetractors.
`Switchesare typically coupled to each detonatoror igniter
`in a string of guns to determine the sequence offiring. One
`type of switch uses a diodethat allows two guns(ora gun and
`a plug) to be fired, one with positive and the other with
`negative voltage. Percussion switches are mechanical devices
`that use the force of detonation of one gun to connect electri-
`cally to the next gun, starting with the bottom gun and work-
`ing up, and are typically used to selectively fire three or more
`guns. The devices also disconnect from the gun just fired,
`preventing the wireline from shorting outelectrically. A prob-
`lem with percussion switches1s that if any switch in thestring
`fails to actuate, the firing sequence cannot continue, and the
`string must be pulled from the wellbore, redressed and run
`again.
`More recently, electronic switches have been used in
`select-fire guns. Unlike percussion-actuated mechanical
`switches, selective firing of guns, continues in the event of a
`misfired gun or a gun that cannotbefired becauseit is flooded
`with wellbore fluid. One commercial switch of this type has
`downlink communication but is limited in the number of
`individual guns that can be fired in one run. As with the
`percussion switches, the system relies on detecting changes in
`current at the surface to identify gun position, which may not
`be a reliable method to identify gun position in a changing
`environment.
`
`Another type of electronic switch has both downlink and
`uplink communication andis not as limited in total number of
`gunsthat can befiled in a, run, but is somewhatslow to fire
`because of the long bi-directional bit sequence required for
`communication. Both downlink and uplink communications
`use a unique address associated with each switch to identify
`correct gun position prior to firing.
`A common problem in operating downhole devices is
`keeping unwanted power from causing catastrophic action.
`Examples include a perforating gun receiving voltage that
`accidentally fires the gun downhole,a setting tool being acti-
`vated prematurely, a release device suddenly deploying, and
`high voltage destroying electronics in a well logging tool
`because the powerrating is exceeded. A solutionto this prob-
`lem is to stop unwanted powerby inserting a blocking mecha-
`nism between the power supply and the downhole device to
`be protected. In a standard perforating job, the powerto log
`and to detonate the perforating gun is located at the surface.
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`Power can also be generated downhole using batteries.
`Recently, there have been detonator designs that incorporate
`electronics to block unwanted power from firing a gun.
`The high voltage needed to power a downholetractor pre-
`sents particular problemsprotecting the tool string conveyed
`by the tractor. The surface voltages powering a tractor are
`typically 1500 VDC or 1000 VAC. Tractors normally have an
`internal design that prevents tractor power from being trans-
`mitted below the tractor, but sometimesthe circuitry fails or
`does not work properly, allowing induced voltage or direct
`voltage to pass through the tractor into the toolstring below.
`To protect the tool string, which can include perforating guns
`or logging tools, one or more special safety subs are located
`between it and the tractor. Some of the subs use electrical/
`
`mechanical relays to block accidental tractor power; others
`use electronic switches that are commandedto turn offand on
`
`using communication messages from the surface that contain
`a unique address.
`Morerecently, the American Petroleum Institute (API) has
`issued a recommendedpracticefor safe tractor operations, RP
`67,
`that
`includes a recommendation that
`the tractor be
`designed to block unwanted voltage from passing through
`and that the design is free of any single point failure. In
`addition, there must be an independent, certified blocking
`device between thetractor and any perforating gun to prevent
`unwanted powerfrom being applied to a gun.
`
`BRIEF SUMMARY OF EXAMPLES OF THE
`INVENTION
`
`An object of the present invention to provide a system that
`prevents tractor power from migrating past the tractor. Ele-
`ments ofthis design are employed in a separate safety sub that
`acts as a safety barrier to block unwanted powerto the tool
`string.
`Another object of the present invention is to provide a
`command and response system featuring fast bi-directional
`communication while allowing a large number of guns to be
`fired selectively. The system requires communication
`through a cable and can include communications with a
`downhole tractor and safety sub. Multiple embodiments are
`provided using a state machine as part ofthe electrical switch
`to command andidentify status within the switch. In one
`embodiment, the gun position before firing is uniquely iden-
`tified by keeping track of the sequence of states. In the
`another, correct gun position is established by state and an
`uplink of a unique identifier. Unlike bi-directional communi-
`cation electronic switches, a returned downlink ofthe identi-
`fier is not necessary.
`Other objects of the present invention, and many advan-
`tages, will be clear to those skilled in the art from the descrip-
`tion of the several embodiment(s) of the invention and the
`drawings appended hereto. Those skilled in the art will also
`recognize that the embodiment(s) described herein are only
`examples of specific embodiment(s), set out for the purpose
`of describing the making and using of the present invention.
`The present invention provides a system for bi-directional
`communication with a tractor that includes means for con-
`necting and disconnecting electrical power belowthetractor.
`The system also allows bi-directional communication to sen-
`sors contained in the tractor for monitoring certain opera-
`tional functions. The communication and uplink data trans-
`mission can occur with tractor power either off or on. A
`separate safety sub uses common elements of the bi-direc-
`tional communication and switching to block unwanted volt-
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 030
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 030
`
`

`

`US 8,576,090 B2
`
`3
`4
`transmitters operating at low and high currentlevels for trans-
`age and to pass allowable voltage. In addition, methods are
`mitting uplink signals through the cable, and a microproces-
`disclosed for disconnecting a shorted wireline below the trac-
`sor in electrical communication with the signal receiving
`tor or below the safety sub.
`means and the first and second transmitters that includes a
`Also provided is a system for bi-directional communica-
`state machinefor validating a signal from the signal receiving
`tion with other devices such as selectively fired perforating
`meansandthat returnsan uplink signal usingeitherthefirst or
`guns, setting tools, release devices and downhole sensors
`said second transmitter through the cable. A switch is respon-
`including a system to select andfire specific guns in thesting.
`sive to an output from the microcontroller when a signal is
`Each switch unit is interrogated and returns a unique address
`validated by the state machine and an explosive initiator is
`that is retrieved under system control from the surface. Each
`location within the gun string is identified with a particular 10 operably connected to the switch.
`address.
`In yet another aspect, the present invention provides an
`invention provides an
`the present
`In another aspect,
`apparatus for checking downhole tools function before low-
`embodiment in which every switch unit is identical without
`ering into a wellbore comprising a pre-check controller, elec-
`an identifying address. Each switch unit’s sequential position
`trical connections between the pre-check controller and one
`in the gun string is identified by keeping proper track of the 15 or more downhole tools, and one or more control units
`numberof surface commands along with the uplink status
`mounted on each downhole toolthat are adapted for bi-direc-
`from an embeddedstate machine. This predetermined chain
`tional communication with the pre-check controller, each
`of events provides surface information for determining the
`control unit comprising a state machine for identifying the
`unique location of each switch unit in a given gun string.
`status of each control unit, the pre-check controller being
`These enhancements allow for faster communication, initial- 20 adapted to send a plurality of commandsto the respective
`ization and firing time. As an addedfeature, all switches are
`control units.
`exactly the same with no unique embeddedaddress to pro-
`Also provided is a method for checking one or more
`gram and manage.
`devices in a tool string before lowering the tool string into a
`Also provided is a method for controlling one or more
`wellbore comprising the steps of sending a signal to control
`devices on a tool string in a wellbore with a surface computer 25 units located on the devices, each control unit comprising a
`and a surface controller comprising the steps of sending a
`state machinefor identifying control unit status, and process-
`signal down a cable extending into the wellbore to one or
`ing the signal with the state machine. The switch(es) located
`more control units located on the devices on the toolstring,
`on the device is/are controlled whenthe state machineforthat
`each control unit comprising a state machine for identifying
`device processes a valid signal and a signal validating switch
`the status of the control unit, processing the signal with the 30 action is returned from the control unit.
`state machine, controlling the position of one or more
`Also provided is acommunication system that allowsserial
`switches located on the device on the tool string when the
`and parallel control of downhole devices including tractors,
`state machine for the device processes a valid signal, and
`auxiliary tractor tools, well logging tools, release mecha-
`returning a signal validating switch action to the surface com-
`nisms, and sensors. The advantage of parallel control is that
`puter.
`35 individual devices can be interrogated without going through
`In another aspect, a method is provided for switching wire-
`a series path, thereby being more accessible. Each toolin the
`line voltage between a tractor motorandthe tractor output in
`parallel arrangement has a control unit that carries a tool
`a downhole tool string including a tractor comprising the
`identifier as part of its uplink communication. A detonator
`steps of sending a signal to a control unit on the tractor from
`that contains an integral switch unit is also provided.
`the surface, processing the signal with a state machine on the 40 Also provided is a system including several components as
`tractor for controlling the position of one or more switches
`follows:
`located in one or more circuits connecting the wireline to
`Tractor
`either the tractor motoror a through wire that connects to the
`1. Use of dual processors, each controlling a set of switches
`tool string; and returning a signal validating switch action to
`for connecting a W/L to either a tractor motor or a tool
`the surface.
`below for directing the wireline for powering the tractor
`Also provided is a method for switching between a safe
`poweror providing a direct through wire mode.
`modefor tractoring and a perforating modefor perforating in
`2. A Zenerdiode in series with the final output to de-couple
`a toolstring including a tractor and a perforating gun that has
`the wireline in case of a short, thereby allowing commu-
`been loweredinto a well on a wireline comprising the steps of
`nication to the micro in order to actuate a switch to
`sending a signal to a control unit on the tractor from the 50
`disconnect a shorted circuit to regain tractor functions.
`surface, processi