USOO8576090B2
`
`(12) Unlted States Patent
`(10) Patent No.:
`US 8,576,090 B2
`
`Lerche et al.
`(45) Date of Patent:
`Nov. 5, 2013
`
`(54) APPARATUS AND METHODS FOR
`CONTROLLING AND COMMUNICATING
`
`WITH DOWNWHOLE DEVICES
`
`(75)
`
`Inventors: Nolan C. Lerche, Stafford, TX (US);
`James E. Brooks, Manvel, TX (US)
`_
`_
`.
`(73) Ass1gnee: Huntlng T1tan, Ltd., Pampa, TX (US)
`
`6,959,765 B2
`7,081,831 B2 *
`7,347,278 B2
`7,530,397 B2
`7,536,942 B2
`7,698,982 132
`2002/0062991 A1
`
`11/2005 Bell
`7/2006 Dodge ....................... 340/8554
`3/2008 Lerche et al.
`5/2009 Bell
`5/2009 Bell
`4/2010 Bell
`5/2002 Farrant
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 15403) by 139 days.
`
`CA
`EP
`
`(21) Appl.No.: 12/221,611
`
`(22)
`
`Filed:
`
`Aug. 5, 2008
`
`2/2010
`2708183 A1
`5/2012
`2229503 Bl
`(Continued)
`OTHER PUBLICATIONS
`
`International Preliminary Report on Patentability, PCT/US09/04477,
`
`(65)
`
`Prior Publication Data
`
`dated Feb 17, 2011, 9 Pages
`
`US 2011/0090091 A1
`
`Apr. 21, 2011
`
`(Continued)
`
`Related US. Application Data
`(63) Continuation-in-part
`of
`application
`PCT/US2008/000200, filed on Jan. 7, 2008.
`
`No.
`
`Primary Examiner 7 Benjamin Fiorello
`(74) Attorney, Agent, or Firm 7 Jason A. Saunders; Arnold,
`KnObIOCh & sawders’ LLP
`
`(51)
`
`Int. Cl.
`E213 43/1185
`(52) US. Cl.
`USPC .................. 340/8532; 340/8553; 340/8557;
`166/66
`
`(2006.01)
`
`(58) Field of Classification Search
`USPC .......... 340/8532, 854.1, 855.3, 855.5, 855.7;
`166/66
`See application file for complete search history.
`
`(56)
`
`References Cited
`US. PATENT DOCUMENTS
`
`j’ggg’fig :
`6,283,227 B1
`6,604,584 B2
`6,938,689 B2
`
`$133? 51:31)
`9/2001 Lerche et al.
`8/2003 Lerche
`9/2005 Farrant
`
`ABSTRACT
`(57)
`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,
`a release mechanism, a unit containing sensors for monitoring
`downhole conditions, a setting tool, and a perforating gun.
`Also provided are apparatus and methods for 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 switches for safety,
`to state machines in the respective control units, each state
`machine returning a signal verifying switch status to the
`surface. Control and power functions are accomplished with
`voltage of different polarities for safety.
`
`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 A1
`2005/0045331 A1
`2006/0130693 A1
`2011/0066378 A1
`
`6/2004 Lerche
`3/2005 Lerche
`6/2006 Teowee
`3/2011 Lerche et al.
`
`FOREIGN PATENT DOCUMENTS
`
`GB
`WO
`WO
`WO
`WO
`
`2340157 A
`0024999 A1
`2007143759 A1
`2008100362 A2
`2010016897
`
`2/2000
`5/2000
`12/2007
`8/2008
`2/2010
`
`OTHER PUBLICATIONS
`
`Examination Report, European Patent Application No. 097410435,
`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, 201 1 European Patent Appli-
`cation No. 100755784, 8 pages.
`File history of European Patent No. 2229503, 290 pages.
`File history of European Patent Application No. 100755784, 180
`pages.
`Response to Communication pursuant to Rules 70(2) and 70a(2) of
`European Patent Application No. 100755784, 8 pages.
`File history ofCanadian Patent Application No. 2,708,183, 61 pages.
`File history ofCanadian Patent Application No. 2,708,007, 30 pages.
`
`File history of European Divisional Patent Application No.
`100757616, 26 pages.
`File history of European Divisional Patent Application No.
`110752029, 141 pages.
`File history of European Divisional Patent Application No.
`110752045, 137 pages.
`Communication pursuant to Article 94(4) EPC, Application No.
`100757616, 4 pages.
`U.S. Appl. No. 12/451,913, filed Dec. 3, 2009, Lerche et al.
`US. Appl. No. 12/934,701, filed Sep. 27, 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/
`USO8/00200, 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.
`
`* cited by examiner
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 002
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 002
`
`

`

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`Ex. 1024
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`
`

`

`U.S. Patent
`
`Nov. 5, 2013
`
`Sheet 5 0f 27
`
`US 8,576,090 B2
`
`
` SURFACE
`APPLIES W/L POWER
`
`TRANSMIT: STATE "0"
`
`
`
`TURN W/L
`POWER OF
`
`TOP SWITCH
`
`
`VERIFY MESSAGE
`
`IF OK
`
`UPLINK:
`
`SWITCH STATUS
`
`STATE MACHINE STATUS
`
`
` SURFACE
`IF NOT 0K
`
`
`UPLINK BAD MESSAGE STATUS
`
`
`
`
`VERFIY:
`MESSAGE VAUDITY
`STATE MACHINE STATUS
`
`IF 0K
`
`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
`
`
`
` SURFACE
`
`VERIFY:
`
`
`MESSAGE VAUDITY
`STATE MACHINE STATUS
`IF OK
`TRANSMIT: STATE ”0"
`IF NOT OK OR NO MESSAGE
`RESTART
`
`
`
`
`
`
`
`
`FIG. 5
`
`CONTINUE TO END
`or SIRING
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 007
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 007
`
`

`

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

`

`U.S. Patent
`
`NOV. 5, 2013
`
`Sheet 7 of 27
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`US 8,576,090 B2
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`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 8 0f 27
`
`US 8,576,090 B2
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`Ex. 1024
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`

`

`U.S. Patent
`
`NOV. 5, 2013
`
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`

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`

`

`U.S. Patent
`
`NOV. 5, 2013
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`US 8,576,090 B2
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`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 13 0f 27
`
`US 8,576,090 B2
`
` SURFACE
`
`APPLY W/L POWER
`
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`STATUS
`
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`
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`
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`MESSAGE VALIDITY
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`
`
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`
`
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`
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`
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`
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`
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`
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`
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`
`
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`
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`
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`
`FIG. 10
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 0 15
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 015
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 14 0f 27
`
`US 8,576,090 B2
`
`POWER-UP
`
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`
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`
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`
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`STATE 5
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`
`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
`
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`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 16 0f 27
`
`US 8,576,090 B2
`
`
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 018
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 018
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 17 0f 27
`
`US 8,576,090 B2
`
`
`
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`
`
`
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`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 019
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 019
`
`

`

`U.S. Patent
`
`25,
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`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 19 0f 27
`
`US 8,576,090 B2
`
`FIG. 16A
`
`
`
`SURFACE
`APPUES W/L POWER
`
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`SWITCH '3'
`
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`RESTART
`
`
`IF 0K
`
`TURN W/L SWITCH ON
`UPUNK:
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`GO INTO HIBERNATTON
`
`
`SURFACE
`IF NOT OK
`
`
`
`VERIFY:
`UPUNK BAD MESSAGE STATUS
`
`MESSAGE VAUDITY
`
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`TRANSMIT STATE '0'
`SWITCH '2'
`
`
`
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`RESTART
`
`IF 0K
`
`
`UPUNK:
`SWITCH STATUS
`
`STATE MACHINE STATUS
`
`IF NOT OK
`VERIFY:
`
`
`UPUNK BAD MESSAGE STATUS
`MESSAGE VAUDITY
`STATE MACHINE STATUS
` OK
`IF OK
`
`TRANSMIT W/L 0N CMD
`
`
`IF NOT OK OR NO MESSAGE
`
`RESTART
`
`OK
`
`9
`
`UPUNK BAD MESSAGE STATUS
`
`SWITCH '2'
`VERIFY MESSAGE
`IF OK
`TURN W/L SWITCH 0N
`UPUNK:
`SWITCH STATUS
`STATE MACHINE STATUS
`co INTO HIBERNATION
`IF NOT OK
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 021
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 021
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 20 0f 27
`
`US 8,576,090 B2
`
`0 S
`
`
`
`URFACE
`
`
`
`
`VERIFY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`IF 0K
`TRANSMIT: STATE I'0"
`IF NOT OK OR NO MESSAGE
`RESTART
`
`
`
`
`
`
`
`
`SWITCH A"I"
`
`
`
`VERIFY MESSAGE
`IF OK
`
`UPUNK:
`
`SWITCH STATUS
`
`STATE MACHINE STATUS
` SURFACE
`
`
`IF NOT OK
`
`VERIFY:
`
`UPUNK BAD MESSAGE STATUS
`
`MESSAGE VAUDITY
`
`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 0N
`
`UPUNK:
`
`SWITCH STATUS
`STATE MACHINE STATUS
`IF NOT OK
`UPUNK BAD MESSAGE STATUS
`
`
`
`
`
`
`
`
`SURFACE
`
`VERIFY:
`
`MESSAGE VAUDITY
`STATE MACHINE STATUS
`IF OK
`
`
`
`TRANSMIT FIRE ON CMD
`SWITCH '1'
`
`
`IF NOT OK OR NO MESSAGE
`
`
`VERIFY MESSAGE
`
`RESTART
`
`
`IF 0K
`TURN FIRE SWITCH 0N
`
`UPUNK:
`
`
`SWITCH STATUS
`
`SURFACE
`
`
`STATE MACHINE STATUS
`
`
`
`
`IF NOT OK
`
`
`
`
`UPUNK BAD MESSAGE STATUS
`
`
`
`VHQIFY:
`MESSAGE VAUDITY
`STATE MACHINE STATUS
`IF OK
`APPLY SHOOTTNG VOLTAGE
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`0"
`
`e
`
`FIG. 163
`
`SWITCH '1'
`FIRES DETONATOR
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 022
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 022
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 21 0f 27
`
`US 8,576,090 B2
`
`POWER-UP
`
`INVAUD
`
`9)
`
`STATE 0
`
`
`
`RESET
`WAIT FOR DOWNUNK MESSAGE
`
`RECEIVE
`MESSAGE #1
`
`STATE 1
`VAUDATE MESSAGE #1
`
`RECEIVE
`INVAUD
`
`MESSAGE
`
`
`UPUNK INVAUD
`
`STATUS MESSAGE
`
`RECEIVE VALID
`
`MESSAGE
`
`
`
` STATE 2
`UPUNK VAUD MESSAGE STATUS
`
`WAIT FOR DOWNUNK MESSAGE
`
`
`
`
`
`
`STATE 3
`STATE 9
`MESSAGE VAUDATE MESSAGE
`N0 CMD ACTION
`
`
`OEGOOE W/L ON OR ARM 0N
`UPUNK INVAUD
`
`
`
`
`VAUD W/L ON
`STATUS MESSAGE
`VALID ARM 0N
`
`MESSAGE
`MESSAGE
`
`
`
`
`
`
`STATE 5
`STATE 4
`TURN W/L SWITCH ON
`TURN ARM SWITCH ON
`
`UPUNK VAUD MESSAGE STATUS
`UPUNK VAUD MESSAGE STATUS
`GO INTO HIBERMTION
`WAIT FOR DOWNUNK MESSAGE
`
`
`
`
`RECEIVE
`
`MESSAGE #3
`
`
`
`
`N0 GMO A3535 ’0
`STATE 6
`
`VAUDATE MESSAGE
`
`
`DECODE FIRE GMO
`UPLINK INVAUD
`
`
`
`STATUS MESSAGE
`
`
`VAUD FIRE ON
`MESSAGE
`
`
`
`'
`EX” ’4
`
`RECEIVE FIRING VOLTAGE
`
`FIG. 17
`
`STATE 7
`TURN FIRE SWITCH 0N
`UPUNK VAUD STATUS MESSAGE
`
`WAIT FOR FIRING VOLTAGE
`
`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
`
`
`
`SURFACE
`APPUES POWER
`
`TRANSMIT STATE '0'
`
`
` SWITCH '3'
`
`
`VERIFY MESSAGE
`IF OK
`TURN W/L
`
`POWER OF
`UPUNK:
`
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`SURFACE
`
`
`
`IF NOT OK
`VERIFY:
`
`
`UPUNK BAD MESSAGE STATUS
`
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`TRANSMIT W/L o~ CMD
`SWITCH "3"
`
`
`IF NOT OK OR NO MESSAGE
`
`VERIFY MESSAGE
`
`RESTART
`
`IF OK
`
`TURN W/L SWITCH ON
`
`UPUNK:
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`
`GO INTO HIBERNATION
`
`
`
`SURFACE
`IF NOT OK
`
`VERIFY:
`
`
`UPUNK BAD MESSAGE STATUS
`
`MESSAGE VAUDITY
`
`
`STATE MACHINE STATUS
`IF OK
`
`TRANSMIT STATE '0'
`
`
`
`IF NOT OK OR NO MESSAGE
`VERIFY MESSAGE
`
`RESTART
`
`IF OK
`
`UPLINK:
`
`
`SWITCH STATUS
`
`
`STATE MACHINE STATUS
`
`SURFACE
`
`
`IF NOT OK
`
`
` VERIFY:
`UPUNK BAD MESSAGE STATUS
`
`
`
`
`SWITCH '2'
`
`MESSAGE VAUDITY
`STATE MACHINE STATUS
`
`OK IF OK
`
`
`TRANSMIT W/L 0N CMD
`IF NOT OK OR NO MESSAGE
`
`
`RESTART
`
`0K
`
`SWITCH '2'
`VERIFY MESSAGE
`IF OK
`TURN W/L SWITCH ON
`UPUNK:
`SWITCH STATUS
`STATE MACHINE STATUS
`GO INTO HIBERNATION
`IF NOT OK
`
`UPUNK BAD MESSAGE STATUS
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 024
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 024
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 23 0f 27
`
`US 8,576,090 B2
`
`
`
`
`
`
`
`
`
` SURFACE
`
`VERIFY:
`MESSAGE VALIDITY
`STATE MACHINE STATUS
`IF OK
`TRANSMIT: STATE '0'
`
`IF NOT OK OR NO MESSAGE
`
`SWITCH '1'
`
`
`RESTART
`
`
`VERIFY MESSAGE
`IF 0K
`
`UPUNK:
`
`SWITCH STATUS
`IF NOT OK
`STATE MACHINE STATUS
`SURFACE
`
`
`VERIFY:
`
`UPUNK BAD MESSAGE STATUS
`
`
`MESSAGE VAUDITY
`
`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
`
`UPUNK:
`
`SWITCH STATUS
`STATE MACHINE STATUS
`
`IF NOT OK
`
`SURFACE
`UPUNK BAD MESSAGE STATUS
`
`
`VERIFY:
`
`MESSAGE VAUDITY
`
`STATE MACHINE STATUS
`
`
`IF OK
`
`
`
`TRANSMIT FIRE ON CMD
`SWITCH '1 '
`
`
`IF NOT OK OR NO MESSAGE
`VERIFY MESSAGE
`
`
`
`RESTART
`IF OK
`TURN HRE SWITCH ON
`
`UPUNK:
`
`
`SWITCH STATUS
`
`SURFACE
`
`
`STATE MACHINE STATUS
`VERIFY:
`
`
`IF NOT OK
`MESSAGE VAUDITY
`
`
`UPUNK BAD MESSAGE STATUS
`
`STATE MACHINE STATUS
`IF 0K
`
`APPLY SHOOTING VOLTAGE
`IF NOT OK OR NO MESSAGE
`
`RESTART
`
`0
`
`0"
`
`FIG. 183
`
`SWITCH '1'
`FIRES DETONATOR
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 025
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 025
`
`

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 24 0f 27
`
`US 8,576,090 B2
`
`p3 n‘
`
`_____
`
`
`
`SENSOR1
`
`l__—__ *_______—_--—'7
`I
`I
`I
`I
`I
`
`MICRO
`
`I l
`
`______ J
`
`W/L RELEASE
`
`II
`
`PS
`MICRO
`RX. 7X
`
`SEWDRZ
`SENSOR 3
`
`:
`i
`I
`I
`I
`L. __________________
`
`SENSOR 4 _,
`
`:
`I
`I
`I
`I
`
`r——-- ———————— j
`
`I
`:
`:
`i
`
`'
`
`I
`PS
`MICRO = '
`RX' 77‘
`05m : I DETO
`I!
`I”
`
`SW I
`
`L____ __W_/L§!’___l
`
`r‘——- ———————— j
`
`l
`i
`Inigo a '
`I
`05,0I I IGNITOR
`1
`I
`II
`I
`L____ __W_/’:.§K’__J
`
`Rx, TX
`
`I
`
`'
`
`I
`
`OPEN
`
`FIG. 19A
`
`GUN
`
`SETTING TOOL
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 026
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 026
`
`

`

`U.S. Patent
`
`v.0N
`
`B02
`
`52mhS
`
`n
`
`US 8,576,090 B2
`
`ne5.3maa55%ve83%
`
`.m8.<28282
`
`
`
`mom.<2.—
`
`5,on
`
`
`
`EdoEzoomega«may.
`
`mm
`
`«08%
`
`5&3.$38
`
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`
`mun_.
`
`(anF
`
`02.83
`
`“fa62
`0268..Joe
`F.50.—(:56
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 027
`
`Hunting Titan, Inc.
`Ex. 1024
`Pg. 027
`
`
`
`

`

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

`

`US. Patent
`
`Nov. 5, 2013
`
`Sheet 27 0f 27
`
`US 8,576,090 B2
`
`POWER—UP
`
`O
`
` STATE 0
`
`RESET
`WAIT FOR DOWNUNK MESSAGE
`
`
`
`RECEIVE
`
`MESSAGE #1
`
`
`
`
`
`
`
`STATE 1
`VALIDATE MESSAGE f1
`VERIFY STATE '0
`VERIFY CRC
`VERIFY MESSAGE LENGTH
`
`
`
`
`
`MESSAGE
`
`
`
`ILLEGAL CMD
`
`STATE 2
`DECODE COMMAND
`
`LEGAL CMD
`
`
`
`FIG. 21
`
`STARE 6
`UPUNK INVAUD
`
`STATUS MESSAGE
`
`INVAUD
`MESSAGE
`
`EVENT INVAUD
`MUST POWER DOWN
`
`STATE 3
`UPUNK VALID MESSAGE STATUS
`STATE POSITION '3'
`DECODED CMD
`ALL STATUS
`EMBEDDED ADDRESS
`(IF USED)
`CRC
`
`WAIT FOR DOWNUNK MESSAGE
`
`RECEIVE
`MESSAGE #2
`
`STATE 4
`VAUDATE MESSAGE f2
`VERIFY STATE '3
`COMPARE CMD TO
`PREVIOUS CMD
`VERIFY CMD
`VERIFY MESSAGE LENGTH
`
`VALID
`MESSAGE
`
`STATE 5
`PROCESS COMMAND
`UPLINK STATUS
`STATE PosmON '5'
`SWITCH STATUS
`EMBEDDED ADDRESS
`(IF USED)
`CRC
`ENTER SLEEP MODE
`MAINTAIN LOGIC STATE
`DO NOT USTEN TO ANYTHING
`
`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. PCTIUSZOOS/OOZOO, TRACTOR COM-
`MUNICATION/CONTROL AND SELECT FIRE PERFO-
`
`RATING SWITCH, filed Jan. 7, 2008, which related patent
`application is hereby incorporated in its entirety by this spe-
`cific reference thereto.
`
`BACKGROUND OF THE INVENTION
`
`5
`
`10
`
`15
`
`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 hydrocarbons to flow into the wellbore. Such
`operations can involve multiple guns that create separate
`perforations in multiple producing zones where, each gun is 20
`fired separately. Operations can also involve single or mul-
`tiple guns in conjunction with setting a plug. The guns are
`typically conveyed to the producing zone(s) by wireline, tub-
`ing or downhole tractors.
`Switches are typically coupled to each detonator or igniter 25
`in a string of guns to determine the sequence of firing. One
`type of switch uses a diode that allows two guns (or a 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- 30
`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 out electrically. A prob-
`lem with percussion switches is that if any switch in the string 35
`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 40
`switches, selective firing of guns, continues in the event of a
`misfired gun or a gun that cannot be fired because it 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 45
`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 50
`uplink communication and is not as limited in total number of
`guns that can be filed in a, run, but is somewhat slow 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 55
`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- 60
`vated prematurely, a release device suddenly deploying, and
`high voltage destroying electronics in a well logging tool
`because the power rating is exceeded. A solution to this prob-
`lem is to stop unwanted power by inserting a blocking mecha-
`nism between the power supply and the downhole device to 65
`be protected. In a standard perforating job, the power to log
`and to detonate the perforating gun is located at the surface.
`
`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 downhole tractor pre-
`sents particular problems protecting 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 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.
`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 commanded to turn offand on
`
`using communication messages from the surface that contain
`a unique address.
`More recently, the American Petroleum Institute (API) has
`issued a recommended practice for 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 the tractor and any perforating gun to prevent
`unwanted power from 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 power to 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 and identify 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 of the 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 below the tractor.
`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
`
`4
`
`transmitters operating at low and high current levels for trans-
`mitting uplink signals through the cable, and a microproces-
`sor in electrical communication with the signal receiving
`means and the first and second transmitters that includes a
`
`3
`age and to pass allowable voltage. In addition, methods are
`disclosed for disconnecting a shorted wireline below the trac-
`tor or below the safety sub.
`Also provided is a system for bi-directional communica-
`state machine for validating a signal from the signal receiving
`tion with other devices such as selectively fired perforating
`means and that returns an uplink signal using either the first or
`guns, setting tools, release devices and downhole sensors
`said second transmitter through the cable. A switch is respon-
`including a system to select and fire specific guns in the sting.
`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
`number of surface commands along with the uplink status
`mounted on each downhole tool that are adapted for bi-direc-
`from an embedded state 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 commands to the respective
`ization and firing time. As an added feature, all switches are
`control units.
`exactly the same with no unique embedded address 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 machine for 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 tool string,
`on the device is/are controlled when the state machine for that
`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 providedis acommunication system that allows serial
`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 tool in the
`line voltage between a tractor motor and the 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 motor or a through wire that connects to the
`l . 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
`power or providing a direct through wire mode.
`mode for tractoring and a perforating mode for perforating in
`2. A Zener diode in series with the final output to de-couple
`a tool string including a tractor and a perforating gun that has
`the wireline in case of a short, thereby allowing commu-
`beenlowered into awell onawireline comprising the steps