`
`US 8,689,868 B2
`(10) Patent No.:
`(12) United States Patent
`
`Lerche et al. Apr. 8, 2014 (45) Date of Patent:
`
`
`(54) TRACTOR COMMUNICATION/CONTROL
`AND SELECT FIRE PERFORATING SWITCH
`SIMULATIONS
`
`(75)
`
`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)
`
`(58) Field of Classification Search
`USPC .......... 166/255.1, 255.2, 251.1, 66; 175/4.51,
`175/24, 45; 340/8533, 853.2, 854.9
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`US. PATENT DOCUMENTS
`
`4,208,966 A
`
`6/1980 Hart
`
`(73) Assignee: Hunting Titan, Inc., Pampa, TX (US)
`
`4’986’183 A
`
`“1991 JaCOb
`(Continued)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 613 days.
`
`(21) Appl. No.:
`
`12/451,913
`
`(22) PCT Flled:
`
`Jan. 7, 2008
`
`(86) PCT NO’:
`§ 371 (0X1),
`(2), (4) Date: May 3, 2010
`
`PCT/US2008/000200
`
`(87) PCT Pub. NO" W02008/100362
`PCT P1111 Date: Aug. 21: 2008
`
`(65)
`
`Prior Publication Data
`
`US 2010/0286800 A1
`Nov. 11, 2010
`.
`.
`Related US Application Data
`(60) Provisional application No. 60/879,169, filed on Jan.
`6, 2007.
`
`(51)
`
`(201201)
`(200601)
`(200601)
`
`Int. Cl-
`E213 47/09
`E213 4 7/024
`E213 44/00
`(52) US. Cl.
`CPC ............... E2IB 47/024 (2013.01); E2IB 44/00
`(2013.01)
`USPC ......... 166/255.1; 166/255.2; 166/66; 175/24;
`175/45
`
`EP
`
`EP
`
`FOREIGN PATENT DOCUMENTS
`2106494
`9/2011
`
`5/2012
`2229503 Bl
`(Continued)
`
`OTHER PUBLICATIONS
`
`Office Action of Canada Patent Application No. 2,708,007, dated
`Apr. 11, 2012, 4 pages.
`
`(Continued)
`
`Primary Examiner 7 Cathleen Hutchins
`(74) Attorney, Agent, or Firm 7 Jason A. Saunders; Arnold,
`Knobloch & Saunders, L.L.P.
`
`ABSTRACT
`(57)
`A aratus and methods for controllin and communicatin
`wijtiji one or more tools in a downhole fool string including T:
`tractor, an auxiliary tractor tool, a logging tool, a safety sub,
`a release 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
`machines in 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
`
` WIL
`
`
`Tractor
`Power Unit
`
`Collectur
`
`
`
`
`
`
`
`
`
`_ _
`
`r
`
`22
`
`24
`
`
`
`1614 18
`12
`10
`
`
`
`
`
`
`
`
`
`
`
`Tractor
`CCL
`Safety
`Sensors
`Perf Gun
`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
`U.S. PATENT DOCUMENTS
`
`6,283,227 B1
`6,604,584 B2
`6,938,689 B2
`6,959,765 B2
`7,347,278 B2
`7,530,397 B2
`7,536,942 B2
`7,698,982 B2
`2002/0062991 A1
`2004/0108114 A1
`2005/0045331 A1
`2006/0130693 A1
`
`9/2001 Lerche et al.
`8/2003 Lerche
`9/2005 Farrant
`11/2005 Bell
`3/2008 Lerche et al.
`5/2009 Bell
`5/2009 Bell
`4/2010 Bell
`5/2002 Farrant
`6/2004 Lerche
`3/2005 Lerche
`6/2006 Teowee
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`GB
`WO
`WO
`WO
`WO
`
`2402555 B1
`2340157 A
`0024999 A1
`2007143759 A1
`2008100362 A2
`2010016897
`
`4/2013
`2/2000
`5/2000
`12/2007
`8/2008
`2/2010
`
`OTHER PUBLICATIONS
`
`Co-pending U.S. Appl. No. 12/221,61 1, 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/USO8/00200 dated Feb. 2, 2009,
`4 pages.
`Written Opinion of the International Searching Authority, PCT/
`U808/00200, dated Feb. 2, 2009, 6 pages.
`International Preliminary Report on Patentability, PCT/USO 8/00200,
`dated Jul. 7, 2009, 7 pages.
`International Search Report of PCT/USO9/04477, dated Mar. 11,
`2010, 6 pages.
`Written Opinion of the International Searching Authority, PCT/
`USO9/04477, 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/
`USO9/04477, filed Jun. 4, 2010, 67 pages.
`File history of European National Phase Application No.
`EP09741043.5, filed Jul. 8, 2010, 61 pages.
`File history of European Patent Application No. 100757616, filed
`Dec. 15, 2010, 68 pages.
`Decision to grant European patent, European Patent Application No.
`100757616, dated Sep. 1, 2011, 1 page.
`Response to Examination Report, European Patent Application No.
`087540555, dated Nov. 12,2010, 8 pages.
`Examination Report, European Patent Application No. 087540555,
`dated Jul. 6, 2010, 6 pages.
`File history of European Patent Application No. 110752029, filed
`Aug. 30, 2011, 63 pages.
`File history of European Patent Application No. 110752045, filed
`Sep. 1, 2011, 62 pages.
`
`European Search Report dated Mar. 11, 2011, EPO Application No.
`100757616, 5 pages.
`European Examination Report of European Application No.
`100757616, dated Apr. 11,2012, 5 pages.
`Response to European Search Report of European Application No.
`110752029, dated Jul. 3, 12 pages.
`Response to European Search Report of European Application No.
`110752045, dated Jul. 3, 11 pages.
`European Search Report dated Jan. 9, 2012, European Application
`No. 110752045, 4 pages.
`European Search Report dated Jan. 9, 2012, European Application
`No. 110752025, 5 pages.
`Response to Office Action of Canada Patent Application No.
`2,708,007, dated Oct. 10, 2012, 25 pages.
`File history of European Patent Application No. 100757616, 20
`pages.
`Response to European Search Report of European Patent Application
`No. 110752029, 12 pages.
`File history of European Patent Application No. 110752045, 71
`pages.
`File history ofCanadian Patent Application No. 2,708,183, 60 pages.
`File history of Canadian Patent Divisional Application No.
`2,708,183, 72 pages.
`File history of European Patent Application No. 097410435, 17
`pages.
`File history of European Patent Application No. 097410435, 197
`pages.
`File history of related co-pending U.S. Appl. No. 12/221,611, 450
`pages.
`File history of related co-pending U.S. Appl. No. 12/934,701, 385
`pages.
`File history of PCT/USO8/00200, filed Jan. 7, 2008, 99 pages.
`File history of PCT/USO9/04477, filed Aug. 5, 2009, 135 pages.
`File history of Canadian National Phase Application 2,708,007, filed
`Jun. 4, 2010, 56 pages.
`File history of European National Phase Application No. 08754055.
`5, filedAug. 6, 2009, Patent No. 2106494, issued Sep. 28, 2011, 396
`pages.
`File history of European National Phase Application No. 10075761.
`6, filed Dec. 15, 2010, 231 pages.
`File history of European National Phase Application No. 11075202.
`9, filed Aug. 30, 201 1, Patent No. 2402555, issued Apr. 3, 2013, 265
`pages.
`File history of European National Phase Application No. 11075204.
`5, filed Sep. 1, 2011, Patent No. 2402556, issued Mar. 20, 2013, 255
`pages.
`File history of Canadian National Phase Application No. 2,708,183,
`filed Jun. 4, 2010, 77 pages.
`File history of European Patent Application No. 097410435, filed
`Aug. 5, 2009, issued May 9, 2012, EP 2229503 292 pages.
`File history of European Patent Application No. 100755784, filed
`Aug. 5, 2008, 196 pages.
`File history of Norwegian Patent No. NO/EP2106494, issued Jan. 2,
`2012, 59 pages.
`File history of co-pending U.S. Appl. No. 12/221,611, filed Aug. 5,
`2008, 40 pages.
`File history of Canadian National Phase Application No. 2,792,007,
`filed Oct. 3, 2012, 75 pages.
`File history of Norwegian Patent No. NO/EP2229503, issued Aug.
`20, 2012, 53 pages.
`Office Action, Canadian Patent Application No. 2,792,007, mailed
`Jul. 15, 2013, 2 pages.
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 002
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 002
`
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`U.S. Patent
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 003
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`
`US. Patent
`
`Apr. 8, 2014
`
`Sheet 2 of 18
`
`US 8,689,868 B2
`
`32
`
`To Wirelina
`
`
`
`
`
`WIL
`
`Switch
`\AAQ/
`Surface Computer
`
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`
`Comprised Of:
`
`
`Per-Check Software
`
`Logging Software
`
`
`Perf Software
`PerflTractor
`
`
`Switch
`Tractor Software
`
`
`
`
`
`//
`Laptop
`
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`
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`
`Tractor
`Power
`Control
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`YL
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 004
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 004
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 3 of 18
`
`US 8,689,868 B2
`
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 005
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 005
`
`
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 4 of 18
`
`US 8,689,868 B2
`
`To Tractor IN
`
`Wireless
`Downlink
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`
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`
`Transmit: State "0'.
`IF NOT OK or NO Message
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`
`Continue to End
`ofString
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`
`
`
`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
`
`US 8,689,868 B2
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`Hunting Titan, Inc.
`Ex. 1023
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`Ex. 1023
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 6 of 18
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`US 8,689,868 B2
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`Hunting Titan, Inc.
`Ex. 1023
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`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 7 of 18
`
`US 8,689,868 B2
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 009
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 009
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet 8 of 18
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`US 8,689,868 B2
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`Hunting Titan, Inc.
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`Apr. 8, 2014
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`US 8,689,868 B2
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 012
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`
`US. Patent
`
`Apr. 8, 2014
`
`Sheet 11 of 18
`
`US 8,689,868 B2
`
`120
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 013
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 013
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet120f18
`
`US 8,689,868 B2
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`Ex.1023
`Pg.014
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 014
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`
`US. Patent
`
`Apr. 8, 2014
`
`Sheet 13 of 18
`
`US 8,689,868 B2
`
`
`ven
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`t
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`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 0 15
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 015
`
`
`
`U.S. Patent
`
`Apr. 8, 2014
`
`Sheet140f18
`
`US 8,689,868 B2
`
`
`
`
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`Hunting Titan, Inc.
`Ex.1023
`Pg.016
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 016
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`US. Patent
`
`Apr. 8, 2014
`
`Sheet 15 of 18
`
`US 8,689,868 B2
`
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`
`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
`
`$30.55
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`Hunting Titan, Inc.
`Ex. 1023
`Pg. 018
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 018
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`8990069
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`Hunting Titan, Inc.
`EX. 1023
`Pg. 019
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 019
`
`
`
`
`
`
`US. Patent
`
`Apr. 8, 2014
`
`Sheet 18 of 18
`
`US 8,689,868 B2
`
`Power-Up State 0
`
`State I
`Validate Message #1
`Verify State "0" /
`Verify CRC
`Verify Message Length
`
`State 4
`.
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`\‘\ Compare Cmd to Previous Cmd
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`Figure 21
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 020
`
`Hunting Titan, Inc.
`Ex. 1023
`Pg. 020
`
`
`
`US 8,689,868 B2
`
`2
`
`1
`TRACTOR COMMUNICATION/CONTROL
`AND SELECT FIRE PERFORATING SWITCH
`SIMULATIONS
`
`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
`work properly, allowing induced voltage or direct voltage to
`pass through the tractor into the tool string below, which can
`include perforating guns or logging tools. To protect the tool
`string, one or more special safety subs are located between it
`and the tractor. Some of the subs use electrical/mechanical
`
`This application claims the benefit of US. Provisional
`Application No. 60/879,169, filed Jan. 6, 2007, which related
`patent application is hereby incorporated in its entirety by this
`specific reference thereto.
`relays to block accidental tractorpower. Others use electronic
`Perforating guns are used in operations to complete an oil
`or gas well by creating a series of tunnels through the casing 10 switches that are commanded to turn off and on using com-
`into the formation, allowing hydrocarbons to flow into the
`munication messages from the surface that contain a unique
`wellbore. Such operations can involve multiple guns that
`address.
`create separate perforations in multiple producing zones
`More recently, theAmerican Petroleum Institute has issued
`where each gun is fired separately. Operations can also
`a recommended practice for safe tractor operations, RP 67,
`involve single or multiple guns in conjunction with setting a 15 which includes arecommendation that the tractorbe designed
`plug. The guns are typically conveyed by wireline, tubing or
`so that it blocks unwanted voltage from passing through and
`downhole tractors.
`that the design is free of any single point failure. In addition,
`Switches are typically coupled to each detonator or igniter
`there must be an independent, certified blocking device
`in a string of guns to determine the sequence of firing. One
`between the tractor and any perforating gun to prevent
`simple type of switch uses a diode that allows two guns (or a 20 unwanted power from being applied to a gun.
`gun and a plug) to be fired, 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 connect electrically to the next one, 25 through a cable and can include communications with a
`starting with the bottom gun and working up. The devices also
`downhole tractor and safety sub. Two embodiments are 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 command and identify 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 sequence of states. 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 event of 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 guns that can be fired in one run. As with the
`unwanted power to the tool string.
`percussion switches, the system relies on detecting changes in 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
`Another type 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 be fired in a run, but is somewhat slow to fire
`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 power from causing catastrophic actions.
`operational functions. The communication and uplink data
`Some examples include a perforating gun receiving voltage
`transmission can occur with tractor power either 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 unwanted volt-
`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 power by 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 and to 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
`a system to select and fire specific guns in a perforating string.
`to block unwanted power from firing a gun.
`In one embodiment each switch unit is interrogated and
`The high voltage necessary to power a downhole tractor 65 returns aunique addressthat is retrieved under system control
`presents particular problems in protecting the tool string it
`from the surface. Each location within the gun string is iden-
`conveys. The surface voltages powering a tractor 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
`
`4
`
`the status of each control unit; and processing the signal with
`the state machine. The position of one or more switches
`located on the device in the tool string is controlled when the
`state machine for that device processes a valid signal and a
`signal validating switch action is returned from the control
`unit.
`
`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
`number of surface commands along with the uplink status
`from an embedded state 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-
`
`Also provided is a communication system than allows both
`serial and parallel control of downhole devices including
`tractors, auxiliary tractor tools, well logging tools, release
`h
`.
`d
`Th
`d
`t
`f
`11 1
`t
`1.
`ization and firing time. As an added feature, all switches are 10
`mhec .aniismis, alndsensors.
`:a van ageo piara. Z con ro 1s
`exactly the same with no unique embedded address to pro-
`t at in 1v1 ua
`ev1ces can e 1nterrogate w1t out gomg
`gram and manage.
`through a ser1es path, thereby being more access1ble. Each
`Also provided is a method for controlling one or more
`tool 1n.the parallel arrangement has a control unlt that carr1es
`devices on a tool string in a wellbore with a surface computer
`and a surface controller comprising the steps of sending a 15 a tool 1dent1fier .as pm of1ts “P111? communication. A deto-
`signal down a cable extending into the wellbore to one or
`nator that contams an integral 5“”ch un1t1s also prov1ded.
`more control units located on the devices in the tool string,
`A150 prov1ded1s a system 1nclud1ng several components, a
`each said control unit comprising a state machine for identi-
`tractor, surface controller, surface computer, and safety 5111’ as
`fying the status ofeach said control unit, processing the signal
`fOHOWSI
`with the state machine, controlling the position of one or more 20
`Tractor
`switches located on the device in the tool string when the state
`1 . Use of dual processors, each controlling a set of switches
`machine for that device processes avalid signal, and returning
`for connecting a W/L to either a tractor motor or a tool
`a signal validating switch action to the surface computer.
`below for directing the wireline for powering the tractor
`In another aspect, a method of switching wireline voltage
`power or providing a direct through wire mode.
`between a tractor motor or the tractor output in a downhole 25
`2. A Zener diode in series with the final output to decouple
`tool string including a tractor is provided. The method com-
`the wireline in case of a short, thereby allowing commu-
`prises the steps of sending a signal to a control unit on the
`nication to the micro in order to actuate a switch to
`tractor from the surface, processing the signal with a state
`disconnect a shorted circuit to regain tractor functions.
`machine on board the tractor for controlling the position of
`3. An inline series transformer on the output of the tractor
`one or more switches located in one or more circuits connect- 30
`with one end ofthe primary winding connecting directly
`ing the wireline to either the tractor motor or a through wire
`to the tractor output while the