DOWNHOLE PERFORATION GUN

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of United States Provisional Patent Application No. 63/638,031, filed on April 24, 2024, and United States Provisional Patent Application No. 63/690,623, filed on September 4, 2024, which are hereby incorporated by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

Wellbores may be drilled into a surface location or seabed for a variety of exploratory or extraction purposes. For example, a wellbore may be drilled to access fluids, such as liquid and gaseous hydrocarbons, stored in subterranean formations and to extract the fluids from the formations. Wellbores used to produce or extract fluids may be formed in subterranean formations using earth-boring tools such as drill bits for drilling wellbores and reamers for enlarging the diameters of wellbores. In some cases, perforations are made into the wellbore and surrounding formations. For instance, these perforations may enable a fracturing fluid to be injected into the formation to form fractures in the formation, as well as to facilitate the efficient flow of production fluids such as oil, gas, or water, into the wellbore from the formation.

SUMMARY

In some embodiments, a device for perforating a wellbore includes a loading tube having a first end and a second end and configured to house one or more shaped charges, the loading tube being positionable within a carrier tube. An adapter is configured to connect to the carrier tube and to connect the carrier tube to a downhole component. The loading tube is fixed to the adapter at the second end of the loading tube and at a first end of the adapter. The adapter includes an adapter electrical connecter at a second end of the adapter. A loading tube electrical connecter is connected to the first end of the loading tube, and a conductor traverses the loading tube connecting the adapter electrical connecter to the loading tube electrical connecter.

In some embodiments, a detonator module for detonating shaped charges in a downhole perforation gun, includes a detonator housing positionable within a carrier tube of the downhole perforation gun, a first detonator electrical connecter on a first end of the detonator housing, and a second detonator electrical connecter on a second end of the detonator housing. The detonator module further includes a detonator charge positioned within the detonator housing and being at least partially exposed to an exterior of the detonator housing, and an addressable switch for detonating the detonator charge based on a first electrical signal.

In some embodiments a system for perforating a wellbore includes a carrier tube having a first end and a second end, and an adapter connected to the carrier tube and having a first end and a second end. The adapter is configured to connect the carrier tube at the second end of the carrier tube to a downhole component. The adapter includes an adapter electrical connecter configured to electrically connect to the downhole component. The system includes a loading tube positioned within the carrier tube and having a first end and a second end and housing one or more shaped charges therein. The loading tube is fixed to the adapter at the second end of the loading tube and at the first end of the adapter and includes a loading tube electrical connecter at the first end of the loading tube. A conductor traverses the loading tube connecting the adapter electrical connecter to the loading tube electrical connecter. The system further includes a detonator module positioned within the carrier tube at the first end of the loading tube. The detonator module includes a detonator housing having a detonator charge positioned therein for detonating the one or more shaped charges.

This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1-1 is an example of a downhole system, according to at least one embodiment of the present disclosure;

FIG. 1-2 is an example of a perforation operation of the downhole system of FIG. 1-1, according to at least one embodiment of the present disclosure;

FIG. 2 illustrates a schematic diagram of a perforation gun, according to at least one embodiment of the present disclosure;

FIG. 3-1 illustrates a side view of a loading tube, according to at least one embodiment of the present disclosure;

FIG. 3-2 illustrates a side cross-sectional view of the loading tube of FIG. 3-1 having shaped charges positioned therein, according to at least one embodiment of the present disclosure;

FIG. 3-3 illustrates a side cross-section view of a perforation gun in which the loading tube of FIGS. 3-1 and 3-2 is positioned, according to at least one embodiment of the present disclosure;

FIG. 3-4 illustrates an end view of a second end of an adapter showing an adapter electrical connecter, according to at least one embodiment of the present disclosure;

FIG. 3-5 illustrates a perspective view of a loading tube electrical connecter, according to at least one embodiment of the present disclosure;

FIG. 3-6 is a first perspective view and FIG. 3-7 is a second perspective view of a detonator module of the perforation gun of FIG. 3-3, according to at least one embodiment of the present disclosure;

FIG. 3-8 is a side view of the detonator module of FIGS. 3-3, 3-6, and 3-7 interfacing with the loading tube of FIGS. 3-1, 3-2, and 3-3, according to at least one embodiment of the present disclosure;

FIG. 4 is a schematic view of an adapter, according to at least one embodiment of the present disclosure; and

FIG. 5-1 is an end view of a first side of an adapter, FIG. 5-2 is a side cross-sectional view of the adapter, and FIG. 5-3 is an end view of a second side of the adapter, according to at least one embodiment of the present disclosure.

DETAILED DESCRIPTION

This disclosure generally relates to perforation guns for forming perforations within wellbores. A perforation gun as described herein includes a loading tube for housing shaped charges which can be detonated to perforate a wellbore, casing, formation, etc. The loading tube is positioned inside of a carrier tube, which may be a downhole tubular for housing, conveying, and/or positioning various components of the perforation gun. For instance, the carrier tube may be connectable to various other downhole tubular components, such as to one or more additional carrier tubes of one or more additional perforations guns.

The carrier tube may be connectable to additional downhole components via an adapter. For instance, the adapter may form a threaded connection with the carrier tube and an adjacent downhole component to connect the carrier tube and the adjacent downhole component together. The adapter may form a seal or bulkhead of the carrier tube such that pressure and/or fluid may not penetrate into the carrier tube. In this way, the carrier tube may be a sealed, pressure vessel to protect the internal components of the perforation gun, for example, until the shaped charges are detonated.

The loading tube may be fixed to the adapter, such as by a weld or other integrally formed connection therebetween. In this way, the loading tube and adapter may be inserted into and assembled with the carrier tube as a single unit or component. The fixed nature of the loading tube to the carrier tube may facilitate a hardwired and/or direct electrical connection between the loading tube and carrier tube, for example, without any detachable, disconnectable, and/or temporary electrical interconnects therebetween, which may provide simplicity and reliability. For instance, an electrical conductor may be hardwired to a loading tube electrical connecter at a first end of the loading tube, and may traverse the loading tube and adapter to connect directly to an adapter electrical connecter at a second end of the adapter. In this way, electrical signals may be reliably transmitted through the perforation gun, for example, to one or more additional perforation guns positioned further downhole on a tool string.

The perforation gun may include a detonator module having various detonating components. For instance, the detonator module may be implemented as a detonator housing having a detonator charge and an addressable detonator switch positioned therein. The detonator module and the loading tube may be modular, separate components which may be inserted into and assembled with the carrier tube separately and independently. For instance, the loading tube and the detonator module may each be inserted into the carrier tube and may be positioned adjacent to one another, thereby forming an electrical connection as well as a ballistic connection therebetween. For instance, a detonator tab of the loading tube may position a detonator cord of the loading tube within a channel of the detonator housing in order to position the detonator cord adjacent the detonator charge to form a ballistic connection therebetween. Additionally, the detonator housing may include first and second detonator electrical connections for electrically connecting to the loading tube as well as to another downhole component to which the perforation gun is connected. In this way, the detonator module may be modular and independent of the loading tube, but may form a ballistic connection with the loading tube for detonating the shaped charges and may form an electrical connection with the loading tube for transmitted one or more electrical signals to and through the loading tube.

Additional details will now be provided regarding systems described herein in relation to illustrative figures portraying example implementations. For example, FIG. 1-1 shows one example of a downhole system 100 for drilling an earth formation 101 to form a wellbore 102, according to at least one embodiment of the present disclosure. The downhole system 100 includes a drill rig 103 used to turn a drilling tool assembly 104 which extends downward into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottomhole assembly (“BHA”) 106, and a bit 110, attached to the downhole end of the drill string 105.

The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 further includes additional downhole drilling tools and/or components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through selected-size nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, and for lifting cuttings out of the wellbore 102 as it is being drilled.

The BHA 106 may include the bit 110, other downhole drilling tools, or other components. An example BHA 106 may include additional or other downhole drilling tools or components (e.g., coupled between the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement-while-drilling (“MWD”) tools, logging-while-drilling (“LWD”) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or dampening tools, other components, or combinations of the foregoing.

In general, the downhole system 100 may include other downhole drilling tools, components, and accessories such as special valves (e.g., kelly cocks, blowout preventers, and safety valves). Additional components included in the downhole system 100 may be considered a part of the drilling tool assembly 104, the drill string 105, or a part of the BHA 106, depending on their locations in the downhole system 100.

The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials. For instance, the bit 110 may be a drill bit suitable for drilling the earth formation 101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other materials downhole, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing lining the wellbore 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to the surface or may be allowed to fall downhole. The bit 110 may include one or more cutting elements for degrading the earth formation 101.

The BHA 106 may further include a rotary steerable system (RSS). The RSS may include directional drilling tools that change a direction of the bit 110, and thereby the trajectory of the wellbore. At least a portion of the RSS may maintain a geostationary position relative to an absolute reference frame, such as one or more of gravity, magnetic north, or true north. Using measurements obtained with the geostationary position, the RSS may locate the bit 110, change the course of the bit 110, and direct the directional drilling tools on a projected trajectory. The RSS may steer the bit 110 in accordance with or based on a trajectory for the bit 110. For example, a trajectory may be determined for directing the bit 110 toward one or more subterranean targets such as an oil or gas reservoir.

FIG. 1-2 is an example of a perforation operation of the downhole system 100 of FIG. 1-1, according to at least one embodiment of the present disclosure. In some cases, after the wellbore 102 (or a phase of the wellbore 102) has been formed, it may be advantageous to perforate the wellbore 102. For instance, perforations 107 may be formed in the wellbore 102 (e.g., and surrounding formation 101) in order to provide a conduit through which fluid may flow between the wellbore 102 and the formation 101. For instance, in some cases, fluid (e.g., a fracturing fluid) may be injected into the formation 101 through the perforations 107 in order to form factures in the formation 101 (e.g., fracking). In some cases, production fluids, reservoir fluids, or other subsurface fluids such as hydrocarbons (e.g., oil and/or gas), water, etc. may flow through the perforations 107 into the wellbore 102. In this way, the perforations 107 may facilitate one or more downhole (e.g., production) operations of the downhole system 100.

In some embodiments, a tool string 111 may be implemented within the wellbore 102 in order to form the perforations 107 therein. For example, the tool string 111 may be implemented after the drill string 105 has formed (some or all) of the wellbore 102, for example, as a later phase or operation of the downhole system 100. The tool string 111 may include one or more perforations guns 112, and in many cases, may include multiple perforation guns 112. The tool string 111 may include various other components not particularly shown in FIG. 1-2, such as packers or plugs, setting tools, release tools, weight tools, etc. The tool string 111 may be conveyed and positioned within the wellbore 102 via a conveyance line, such as a wireline cable, coiled tubing, etc.

The perforation guns 112 include one or more ballistic charges, or shaped charges, which may be detonated in order to form the perforations 107. For example, the shaped charges may be shaped, positioned, and/or oriented within a given perforation gun 112 such that, upon detonating, they form the perforations 107 at specific locations, intervals, orientations, angles, etc. within the wellbore 102 and with respect to the formation 101.

In some cases, it may be desirable to form the perforations 107 at various locations that are spread out or spaced at desired locations within the wellbore 102. For example, in some cases, it may be beneficial to form the perforations 107 at intervals and/or spacing that is different than the intervals and/or spacing with which the perforations guns 112 are connected or joined. For instance, in some cases, one or more perforations guns 112 may detonate their shaped charges and form perforations, after which the tool string 111 may be moved and positioned at another location (e.g., partially withdrawn from the wellbore 102) before detonating the charges of additional perforation guns to form additional perforations at one or more additional locations (e.g., shown in phantom in FIG. 1-2). Thus, it may be desirable that the multiple perforation guns 112 of the tool string be detonatable separately such that the perforations 107 may be formed at desired locations of the wellbore 102. For instance, spacing the perforations in this way may facilitate fluid flow into and/or out of the wellbore 102 over a larger area within the formation 101. Accordingly, perforation gun systems and related components are described herein which may facilitate communicating to specifically addressable perforation guns in order to independently detonate the perforation guns, while also providing pressure and fluid seals between the perforation guns to prevent fluid flow to one or more (e.g., undetonated) perforation guns.

FIG. 2 illustrates a schematic diagram of a perforation gun 212, according to at least one embodiment of the present disclosure. The perforation gun 212 may be a downhole perforation gun for operating in a downhole environment, and may be illustrative of the perforation guns 112 as shown and described herein in connection with FIG. 1-2, or any other perforation gun as described herein, including in the appended claims.

The perforation gun 212 includes a carrier tube 220. The carrier tube 220 may be a downhole tubular, pipe, or other tubular component. For example, the carrier tube 220 may be implemented within a wellbore for housing and/or protecting one or more components as described herein, and/or may be implemented within one or more other components or tubulars. The carrier tube 220 may have a first end 290 and a second end 292 opposite the first end 290. The first end 290 may be an uphole end and the second end 292 may be a downhole end of the carrier tube 220 (or vice versa).

The carrier tube 220 may be configured to connect to one or more additional downhole components. For example, the carrier tube 220 may connect to a first downhole component 228 at the first end 290. In some cases, the first downhole component 228 is a component positioned uphole of the perforation gun 212. In other cases, the first downhole component 228 may be positioned downhole of the perforation gun 212. The first downhole component 228 may be another carrier tube 220, for example, of another perforation gun as described herein. The first downhole component 228 may be a top sub for administering a string of multiple perforation guns. The first downhole component may be any other downhole component to which the carrier tube 220 may connect.

In some examples, the carrier tube 220 may connect to a second downhole component 230 at the second end 292. The second downhole component 230 may be a component that is positioned downhole of the perforation gun 212, or else may be positioned uphole of the perforation gun 212. In some cases, the second downhole component 230 is another carrier tube 220 of another perforation gun. The second downhole component 230 may be any other downhole component to which the carrier tube 220 may connect. In some embodiments, the carrier tube 220 may be connected to the first downhole component 228 and not to the second downhole component 230, may be connected to the second downhole component 230 and not to the first downhole component 228, or may be connected to both the first downhole component 228 and the second downhole component 230.

In some embodiments, the carrier tube 220 connects to the second downhole component 230 via an adapter 224. For example, the adapter 224 may form a connection with the carrier tube 220, and may also form a connection with the second downhole component 230. In some embodiments, either (or both) of these connections is a threaded connection, such as with straight threads, tapered threads, etc., or may be another mechanical connection. The adapter 224 may have a first end 265 and a second end 266 opposite the first end 265. In some embodiments, the adapter 224 may facilitate the carrier tube 220 and the second downhole component 230 abutting, contacting, or shouldering against each other. For example, the adapter 224 may be internal to both the carrier tube 220 and the second downhole component 230. In this way, the adapter 224 may facilitate connecting the carrier tube 220 to one or more additional components (e.g., downhole of the carrier tube 220). In some cases, the carrier tube 220 may connect to the first downhole component 228 via an adapter (e.g., the same or similar to adapter to the adapter 224), or else may connect to the first downhole component 228 through another suitable connection.

Based on the connection of the carrier tube 220 with the first downhole component 228 and with the second downhole component 230 (e.g., with one or more adapters 224), the carrier tube 220 may form a pressure vessel (e.g., before firing or detonating the perforation gun 212). For example, an internal pressure of the carrier tube 220 may be sealed from a pressure of the first downhole component 228, of the second downhole component 230, and of an annular space 287 around the carrier tube 220 (e.g., between the carrier tube 220 and the formation such as the formation 101). In particular, the carrier tube 220 may form a fluid and pressure seal at the connection with the adapter 224 such that pressure and/or fluid may not penetrate into the internal space of the carrier tube 220 from the (e.g., downhole) direction of the second downhole component 230. For instance, in a case where the second downhole component 230 is an additional perforation gun, once the additional perforation gun is detonated, fluid and/or pressure from the wellbore, formation, etc. may not flow into the carrier tube 220.

In some embodiments, the perforation gun 212 includes a loading tube 222. The loading tube 222 may have a first end 263 and a second end 264 opposite the first end 263. The loading tube 222 may be a tube, housing, structure, or component which may house, position and/or support one or more shaped charges 236. For example, the loading tube 222 may position the shaped charges 236 in order that the shaped charges 236 may be oriented at a specific interval and/or in a specific direction to form perforations in the wellbore. For instance, the shaped charges 236, when detonated, may form one or more holes or openings in the carrier tube 220. In some cases, the carrier tube 220 includes one or more features, such as one or more grooves, indentations, or other geometries which may facilitate the shaped charges 236 penetrating through the carrier tube 220.

The loading tube 222 may be positioned or housed within the carrier tube 220. For example, the loading tube 222 may be connected to the adapter 224, which may facilitate positioning the loading tube 222 within the carrier tube 220. In some cases, the loading tube 222 may be centered in the carrier tube 220, such as positioned concentrically with the carrier tube 220, or otherwise positioned within the carrier tube 220. The loading tube 222 and the adapter 224 may be connected at the second end 264 of the loading tube 222 and the first end 265 of the adapter 224. The loading tube 222 may be fixed to the adapter 224, such as permanently or semi-permanently fixed. For example, the loading tube 222 may be welded to the adapter 224. The loading tube 222 may be fixed to the adapter 224 with one or more of a weld, braze, adhesive, mechanical connection, or other permanent or semi-permanent connection. In some cases, the loading tube 222 may be integrally formed with the adapter 224, such as the loading tube 222 and the adapter 224 being machined, cast, or otherwise formed as one continuous part. The loading tube being fixed to the adapter 224 in this way may provide reliability as well as ease of installation and/or assembly of the loading tube 222 in the carrier tube 220. For example, some conventional perforation guns may rely on assembling a loading tube to an adapter-like component via a removable connection and/or independently positioning these components within the carrier tube, requiring additional steps of assembly as well as introducing additional points of failure of the conventional perforation gun.

In some embodiments, the perforation gun 212 includes a detonator module 226. The detonator module may have a first end 260 and a second end 261 opposite the first end 260. The detonator module 226 may facilitate firing the perforation gun 212, such as by detonating the one or more shaped charges of the loading tube 222. For example, the detonator module 226 may include a detonator charge 239 which may be a ballistic element that may ignite, explode, or otherwise detonate in order to facilitate a detonation of the shaped charges in the loading tube 222. For instance, the detonator module 226 may form a ballistic connection 234 with the loading tube 222 for detonating the shaped charges 236. The ballistic connection 234 may be formed via a detonator cord of the loading tube 222 extending into the detonator module 226 and/or being positioned adjacent the detonator charge 239 as described herein.

The detonator module 226 may include a detonator switch 238 which may ignite, light, or otherwise cause the detonator charge 239 to detonate. In some cases, the detonator switch relays or passes an electrical power (e.g., generated elsewhere) to cause the detonator to ignite. The detonator switch 238 may be implemented via various electronics, for example, such as a processor, a power supply, and/or other electronic componentry. The detonator switch 238 may be addressable and may be configured for receiving unique communication specifically addressed for the addressable detonator switch 238. For instance, the detonator switch 238 may have a unique identifier, such as a machine (MAC) address, token, or other identifier, which may facilitate selectively communicating with the detonator switch 238, for example, to selectively activate or detonate the perforation gun 212 (e.g., independent of one or more other perforation guns). In this way the detonator module 226 may facilitate detonating the shaped charges 236 based on receiving an electrical signal with the detonator switch 238.

In some embodiments, the detonator module 226 is electronically connected to the first downhole component 228 via an electrical connection 232-1 at the first end 260. For example, the detonator module 226 may include a first detonator electrical connecter 240 at the first (e.g., uphole) end 260 of the detonator module 226 which may connect to a corresponding electrical connecter of the first downhole component 228. The electrical connection 232-1 may be a detachable or disconnectable connection such as an electrical contact connection. One or more electrical signals may be transmitted to the detonator module 226 through the electrical connection 232-1 from the first downhole component 228 (e.g., as transmitted from one or other components, such as from the surface). For example, an electrical signal for firing the perforation gun 212 may be transmitted to the detonator module 226 via the electrical connection 232-1.

In some embodiments, the detonator module 226 is electrically connected to the loading tube 222 via an electrical connection 232-2. The electrical connection 232-2 may be at the second end 261 of the detonator module 226 and at the first end 263 of the loading tube 222. For example, the detonator module 226 may include a second detonator electrical connecter 242 at the second (e.g., downhole) end 261 of the detonator module 226 which may connect to a loading tube electrical connecter 244 at the first (e.g., uphole) end 263 of the loading tube 222. The electrical connection 232-2 may be a detachable or disconnectable electrical connection such as an electrical contact connection.

In some cases, the adapter 224 is electrically connected to the second downhole component 230 via an electrical connection 232-3 at the second end 266 of the adapter 224. For example, the adapter 224 may include an adapter electrical connecter 246 at the second (e.g., downhole) end 266 of the adapter 224 which may connect to a corresponding connecter of the second downhole component 230. The electrical connection 232-3 may be a detachable or disconnectable connection such as an electrical contact connection.

In some embodiments, the loading tube 222 is electrically connected to the adapter 224. For example, in accordance with at least one embodiment of the present disclosure, the loading tube 222 and the adapter 224 may be electrically connected through a hardwired connection or interface. For example, a conductor 248, such as a physical wire or other conductor, may traverse the loading tube 222 and the adapter 224 and may connect to both the loading tube electrical connecter 244 and the adapter electrical connecter 246. The loading tube 222 and the adapter 224 being electrically connected via the conductor 248 may be advantageous in that such a connection is hardwired and doesn’t require any (e.g., detachable) electrical connecters between the loading tube 222 and the adapter 224. The hardwired nature of the electrical interconnect between the loading tube 222 and the adapter 224 may be achieved based on the fixed (e.g., permanent or semi-permanent) connection of the loading tube 222 with the adapter 224. For example, because the loading tube 222 and the adapter 224 are not implemented as separate, connectable parts, but rather are implemented fixed to one another, the conductor 248 may traverse these two components for directly connecting and/or hardwiring the loading tube electrical connecter 244 to the adapter electrical connecter 246. Accordingly, the electrical connection via the conductor 248 may be simpler, may require fewer parts, and may be more reliable compared to conventional perforation gun assemblies. In this way, the conductor 248 may facilitate electrically connecting the detonator module 226 to the second downhole component 230.

In this way, one or more electrical signals may be transmitted and/or relayed through the perforation gun 212. For example, one or more electrical signals may be received by the detonator module 226 (e.g., through the electrical connection 232-1) and may be transmitted or relayed by the detonator module 226 to the second downhole component 230 through the electrical connection 232-2, the conductor 248, and the electrical connection 232-3. For instance, these one or more electrical signals may be addressed and/or intended for the second downhole component 230 (or other component further along the tool string), for example, for selectively detonating one or more perforation guns further downhole of the perforation gun 212.

In some embodiments, the loading tube 222 and the detonator module 226 may be separate, independent, discrete, and/or modular components. For example, the detonator module 226 may not be physically fixed, connected to, or included as part of the loading tube 222 (or vice versa), but rather, each of these components may be separate and may be separately insertable and positionable within the carrier tube 220. For example, the electrical connection 232-2 (e.g., via a contact of the second detonator electrical connecter 242 with the loading tube electrical connecter 244) and the ballistic connection 234 may each be a removable, detachable, and/or disconnectable connection between the loading tube 222 and the detonator module 226. In this way, the detonator module 226 may be inserted and positioned within the carrier tube 220 separate from the loading tube 222, after which the loading tube 222 may be inserted and positioned in the carrier tube 220 (or vice versa) and the electrical connection 232-2 and ballistic connection 234 may each be made therebetween. For instance, the electrical connection 232-2 and the ballistic connection 234 may each be made by inserting and positioning adjacent the detonator module 226 and the loading tube 222 into the carrier tube 220. This separate, modular nature of the detonator module 226 and the loading tube 222 may facilitate transporting, assembling, and/or handling the perforation gun 212 in an unarmed, inactive, or inert state (e.g., the detonator charge 239 being disconnected from the shaped charges 236) while facilitating a simple, efficient assembly thereof to assemble and arm the perforation gun 212.

FIG. 3-1 illustrates a side view of a loading tube 322, according to at least one embodiment of the present disclosure. FIG. 3-2 illustrates a side cross-sectional view of the loading tube 322 having shaped charges 336 positioned therein, according to at least one embodiment of the present disclosure. FIG. 3-3 illustrates a side cross-sectional view of a perforation gun 312 in which the loading tube 322 is positioned, according to at least one embodiment of the present disclosure. FIGS. 3-1, 3-2, and 3-3 will be discussed together, with occasional reference to a specific figure.

The loading tube 322 may be a tube, structure, or other component for housing, holding, and/or carrying one or more shaped charges 336 as described herein. For instance, the shaped charges 336 may be positioned within and/or oriented toward one or more openings 337 within the loading tube 322. The shaped charges 336 may be secured and maintained within the loading tube 322 by any suitable means. The loading tube 322 may have a first end 363 and a second end 364. The perforation gun 312 may be positioned within a wellbore such that the first end 363 is an uphole end and the second end 364 is a downhole end of the loading tube 322 (or vice versa).

The loading tube 322 may include a detonator cord 352. The detonator cord 352 may be a cord, tube, line, fuse, wick, or other equivalent component which may light, ignite, or otherwise combust in order to detonate the shaped charges 236. For example, the detonator cord 352 may be connected to the one or more shaped charges 336 in sequence such that the detonator cord 352 may be activated in order to ignite or detonate the shaped charges 336. For instance, the detonator cord 352 may span a length of the loading tube 322, and in some cases may spiral around the inside or outside of the loading tube 322 (or follow any other pattern) in order to connect to each of the shaped charges 336. The detonator cord 352 may be activated or commenced by a detonator charge as described herein. In this way, the shaped charges 336 may be positioned and detonated via the loading tube 322.

The loading tube 322 may be positioned or positionable within a carrier tube 320. The carrier tube 320 may be a tubular structure or housing which may house the various components of the perforation gun 312, for example, to facilitate conveying and positioning the perforation gun 312 and sharped charges 236 within a wellbore. The carrier tube 320 may be connected to a first downhole component 328 and/or a second downhole component 330. For example, the first downhole component 328 and/or the second downhole component 330 may be a carrier tube of an additional perforation gun, a sub for administering or controlling one or more perforations guns, or another downhole component or tool.

The loading tube 322 may be connected to an adapter 324. For instance, the loading tube 322 may be connected to the adapter 324 via a weld, or any other permanent or semi-permanent connection as described herein. The adapter 324 may have a first end 365 and a second end 366. The perforation gun 312 may be positioned within a wellbore such that the first end 365 is an uphole end and the second end 366 is a downhole end of the adapter 324 (or vice versa). The adapter 324 may connect to the carrier tube 320 via a threaded connection, or other mechanical connection, and may facilitate connecting the carrier tube 320 to the second downhole component 330. In some embodiments, the carrier tube 320 is connected to the first downhole component 328 via an adapter that is the same as or similar to the adapter 324.

The adapter 324 may include an adapter electrical connecter 346. The adapter electrical connecter 346 may be positioned at the second end 366 of the adapter 324, such as on an outer surface of the adapter 324. FIG. 3-4 illustrates an end view of the second end 364 of the adapter 324 showing the adapter electrical connecter 346, according to at least one embodiment of the present disclosure. The adapter electrical connecter 346 may include any componentry for making a removable, detachable, and/or non-permanent electrical connection with another component. For example, the adapter electrical connecter 346 may include an electrical contact, pad, receptacle, plug, spring, or other componentry for facilitating an electrical connection. In accordance with at least one embodiment of the present disclosure, the adapter electrical connecter 346 includes a printed circuit board (PCB) 354 having a contact pad 355 disposed thereon. For instance, the PCB 354 may be positioned on the adapter 324 and configured to interface and/or connect with an electrical contact of the second downhole component 330, such as a spring contact, a detent, or other mating electrical contact. For example, in some cases the second downhole component 330 may be an additional perforation gun and the contact pad 355 interfaces with a detonator module of the additional perforation gun.

In some embodiments, the conductor 348 extends through the adapter 324 and is electrically coupled to the contact pad 355 via an electrical trace on the PCB 354. For example, the conductor 348 may be connected (e.g., soldered) to an electrical trace on the PCB 354 on a side of the PCB 354 facing the inner bore 368, and the electrical trace may pass through the PCB 354 and may electrically connect to the contact pad 355on the opposite side of the PCB 354, facing the second downhole component 330. In some cases, the conductor 348 may be soldered or otherwise electrically connected to the contact pad 355 directly.

With reference again to FIGS. 3-1 to 3-3, the loading tube 322 may include a loading tube electrical connecter 344. For example, the loading tube electrical connecter 344 may be positioned at the first end 363 of the loading tube 322. In some cases, the loading tube electrical connecter 344 may be sized and positioned to contact an inner surface or inner diameter of the carrier tube 320. For example, the loading tube electrical connecter 344 may facilitate supporting the first end 363 of the loading tube 322, such as positioning, situating, and/or centering the loading tube 322 within the carrier tube 320.

FIG. 3-5 illustrates a perspective view of the loading tube electrical connecter 344, according to at least one embodiment of the present disclosure. Similar to the adapter electrical connecter 346, the loading tube electrical connecter 344 may be configured with any componentry for making a removable, detachable, and/or non-permanent electrical connection with another component, such as an electrical contact, pad, receptacle, plug, spring, or other componentry. In accordance with at least one embodiment of the present disclosure, the loading tube electrical connecter 344 includes a PCB 356 having a contact pad 357 disposed thereon. For instance, the PCB 356 may be positioned on the loading tube 322 and configured to interface and/or connect with an electrical contact of a detonator module 326 as described herein. The PCB 356 may be round, partially round, and/or may have one or more rounded edges, for example, for contacting and/or positioning the PCB 356 within the loading tube 322. The contact pad 357 may be connected to the conductor 348 of the loading tube 322 as described herein. For example, the conductor 348 may be soldered or otherwise electrically connected to an electrical trace 390 in the PCB 356. The conductor 348 may be connected to the electrical trace 390 on a bottom side (e.g., in the orientation shown in FIG. 3-5) of the PCB 356, and the electrical trace 390 may pass through the PCB 356 to electrically connect to the contact pad 357 on an opposite (e.g., top) side of the PCB 356.

With reference again to FIGS. 3-1 to 3-3, the loading tube 322, as just mentioned, includes a conductor 348. The conductor 348 may be connected to both the loading tube electrical connecter 344 and the adapter electrical connecter 346, for example, to form a direct, hard-wired connection therebetween. In some embodiments, the conductor 348 is a wire that traverses the loading tube 322 and the adapter 324. The conductor 348 may spiral or wrap around an inside and/or an outside of the loading tube 322. The conductor 348 may be implemented as any other circuit, electrical path, or componentry which may directly connect or hard wire the loading tube electrical connecter 344 to the adapter electrical connecter 346. In this way, the conductor 348 may facilitate transmitting one or more electrical signals between the loading tube electrical connecter 344 and the adapter electrical connecter 346.

The conductor 348 may pass through the adapter 324 within the adapter 324, or at an inner portion of the adapter 324. For example, as shown in FIGS. 3-2 and 3-3, the adapter 324 may include an inner bore 368, passage, or opening. As mentioned herein, the adapter 324 may form a seal with the carrier tube 320, and may act as a bulkhead to create a pressure vessel of the carrier tube 320. The inner bore 368 may provide a passage for the conductor 348 to pass through while maintaining the pressure seal with the carrier tube 320.

The conductor 348 may pass through the inner bore 368 and may connect to the adapter electrical connecter 346 as described herein. The adapter 324 may include a seal 369 positioned within the inner bore 368 which may seal a pressure of the inner bore 368, for example, against the conductor 348. For example, the seal 369 may be a gasket, O-ring, V-ring, or other sealing member which may compress against a sealing surface 367 (e.g., a reduced diameter) of the inner bore 368, may compress against an inner diameter of the inner bore 368, and/or may compress against an outer diameter of the conductor 348. In this way, the seal 369 may energize and may seal against the inner bore and against the conductor 348 such that the integrity of the adapter 324 for functioning as a bulkhead of the carrier tube 320 may be maintained. For example, in some cases, fluid and/or pressure may act on the adapter 324 and/or the seal 369 from the direction of the second end 366 of the adapter 324, and the seal 369 may seal any pressure and/or fluid from flowing into the carrier tube 320. For instance, in the case where the second downhole component 330 is another perforation gun, after that perforation gun is fired, pressure and/or fluid may enter that perforation gun, and may act on the adapter 324 and the seal 369.

In some embodiments, the seal 369 may particularly interface with a conductor core 385 of the conductor 348. For example, the conductor 348 (e.g., a wire conductor) may include a jacket 380 or insulation for electrically insulating the conductor 348. The jacket 380 of the conductor 348 may be stripped or terminated at or near the seal 369 such that the bare conductor, or conductor core 385, engages or interfaces with the seal 369. This may facilitate maintaining the integrity of the pressure and/or fluid seal between the seal 369 and the conductor 348. For example, wire conductors may typically not be configured to prevent fluid and/or pressure from penetrating between the conductor core 385 and the jacket 380, and accordingly, the interface between the conductor core 385 and the jacket 380 may introduce a point of failure of the seal 369. Accordingly, by exposing the bare conductor core 385 to the seal 369, for example, rather than a jacket 380 and/or an insulated conductor, the pressure and/or fluid seal may be maintained. In some cases, the conductor 348 may be a wire conductor having a solid core, for example rather than a stranded or multi-conductor core such that pressure and/or fluid may not penetrate throughout a (e.g., stranded) conductor core 385 of the conductor 348. In some embodiments, the conductor core 385 may be adhered to the seal 369, for example with a glue or adhesive in order to provide a reliable seal therebetween.

In some embodiments, the inner bore 368 may include a sealant 370 situated between the conductor core 385 and the inner diameter of the inner bore 368. For example, the sealant may be positioned to fill the inner bore 368. The sealant may be an epoxy, silicone, polymer, or other sealant which may fill in the inner bore 368. In some embodiments, the sealant 370 is electrically insulating, for instance, to electrically insulate the conductor core 385 from the adapter 324. In some embodiments, the sealant 370 may provide at least some fluid and/or pressure sealing functionality. For example, the sealant 370 may withstand pressure and/or fluid acting on the sealant 370 to at least some degree and for at least some duration. In some embodiments, the sealant 370 may facilitate energizing the seal 369. For example, the fluid and/or pressure acting on the sealant 370 may transmit force to the seal 369, which may act to deform, energize, or otherwise activate the seal 369. In this way, the adapter 324 may include the seal 369 and the sealant 370 within the inner bore 368, for example, to position, seal, and electrically insulate the conductor 348. While the seal 369 is shown as being positioned at or near the first end 365 of the adapter 324, in some cases, the seal 369 may be positioned at any lateral position with the inner bore 368.

As shown in FIG. 3-3, the perforation gun 312 may include a detonator module 326. The detonator module 326 may have a detonator housing 327 having a first end 360 and a second end 361 opposite the first end 360. The first end 360 may be an uphole end and the second end 361 may be a downhole end (or vice versa) of the detonator housing 327. The detonator module 326 may be positioned within the carrier tube 320 adjacent the loading tube 322 at the first end of the loading tube 322. For example, the second end 361 of the detonator housing 327 may contact and/or abut the first end 363 of the loading tube 322.

The detonator module 326 may include a detonator charge 339. The detonator charge 339 may be an explosive or ballistic element which may commence the ballistic process of the firing the perforation gun 312 as described herein. For example, the detonator charge 339 may be positioned near a portion of the detonator cord 352 in order to light, ignite, and/or activate the detonator cord 352, and accordingly detonate the shaped charges 336, as described herein.

FIG. 3-6 is a first perspective view and FIG. 3-7 is second perspective view of the detonator module 326, according to at least one embodiment of the present disclosure. FIG. 3-8 is a side view of the detonator module 326 interfacing with the loading tube 322, according to at least one embodiment of the present disclosure. The detonator charge 339 may be positioned and/or oriented such that at least a portion of the detonator charge 339 is at least partially exposed to an exterior of the detonator housing 327. For example, detonator housing 327 may include an aperture 372 through an outer surface of the detonator housing 327, and the detonator charge 339 may be positioned within the detonator housing 327 and at least partially extending toward or through the aperture 372. The aperture 372 may provide for a ballistic connection of the detonator charge 339 through the detonator housing 327, for example, to a detonator cord positioned adjacent the aperture 372 as described herein.

With reference again to FIGS. 3-1 to 3-3, in some embodiments, the loading tube 322 includes a detonator tab 350 extending from the loading tube 322 at the first end 363 of the loading tube 322. The detonator tab 350 may be a tab, protrusion, or other structure which may extend longitudinally from the loading tube 322 (e.g., into the detonator housing 327 as described herein). The detonator tab 350 may support and/or position an end of the detonator cord 352. For example, the detonator cord 352 may be wrapped about, may pass through, and/or may be fixed or connected to the detonator tab 350 such that the end of the detonator cord 352 may also extend from the loading tube 322. As shown in FIG. 3-5, the detonator tab 350 may position the detonator cord 352, for example, by the detonator cord 352 being intertwined through the detonator tab 350, or by being otherwise connected or supported by the detonator tab 350 by any other suitable means.

As shown in FIG. 3-3, the detonator tab 350 may be positionable within, at, or near the detonator module 326. For instance, the detonator tab 350 may extend from the loading tube 322 and may extend to, toward, and/or within the detonator module 326. For instance, as shown in FIGS. 3-6 to 3-8, the detonator housing 327 may include a detonator channel 374 formed therein, such as on an outer surface of the detonator housing 327. The aperture 372 may be positioned within the detonator channel 374. The detonator tab 350 may be sized, positioned, and configured to fit within and/or mate with the detonator channel 374. For example, the detonator channel 374 may be a channel, groove, hole, slot, connection, or other structure, opening, or feature for directing, positioning, aligning, and/or maintaining the detonator tab 350 with respect to the detonator charger 339. In some embodiments, the detonator channel 374 (e.g., or similar features) may be implemented as a hole, slot, or opening to an interior volume or space of the detonator housing 327, and the detonator tab 350 may accordingly be inserted into the housing such that the detonator cord 352 may be positioned near or adjacent the detonator charge 339. In this way, the detonator channel 374, detonator charge 339, aperture 372, etc., may not be limited to being positioned on an exterior of the detonator housing 327, but rather, one or more of these features may be included (or omitted) at an internal position or within the detonator housing 327.

The detonator tab 350 interfacing with the detonator channel 374 in this way may facilitate positioning and/or aligning the detonator cord 352 with the detonator charge 339 at the aperture 372. For instance, the detonator tab 350 may position the detonator cord 352 at, over, or near the aperture 372 such that the detonator cord 352 and the detonator charge 339 may be ballistically connected. In some embodiments, the detonator charge 339 and the detonator cord 352 may contact, touch, or abut, or these components may otherwise be positioned near each other (e.g., not touching) such that the detonator charge 339 may ignite the detonator cord 352. In some embodiments, the detonator channel 374 may include an inner channel 375, for example, in which the detonator cord 352 may be positioned. In this way, loading tube 322 may be positioned within the carrier tube 320 separate from the detonator module 326, and the detonator tab 350 and detonator cord 352 may slide into the detonator channel 374 in order to ballistically connect the detonator module 326 and the loading tube 322 in a simple, efficient, and seamless manner.

With reference to FIG. 3-3, the detonator module 326 may include a first detonator electrical connecter 340 at the first end 360 of the detonator housing 327 and a second detonator electrical connecter 342 at the second end 361 of the detonator housing 327. The first detonator electrical connecter 340 and/or the second detonator electrical connecter 342 may include any electrical componentry suitable for forming a detachable, disconnectable and/or non-permanent electrical connection with another, mating electrical connecter. For example, in some cases, one or more of these detonator electrical connecters may form a contact electrical connection with a mating electrical component. In some cases, as shown in FIGS. 3-6 and 3-7, the first detonator electrical connecter 340 and the second detonator electrical connecter 342 may include one or more detents, compliant members, springs, etc., for facilitating forming an electrical connection with a mating electrical connecter to which it abuts. As shown in FIG. 3-7, the detonator module 326 may include a ground electrical connecter 386 for establishing a ground with or within the perforation gun 312. For instance, the ground electrical connecter 386 may connect to another mating ground electrical connecter of the first downhole component 328, for example, which may ground one or more of the carrier tube 320, loading tube, adapter 324, etc. In one example, the ground electrical connecter 386 may be positioned and configured to contact (e.g., and establish a ground via) a ground surface 391 (FIG. 3-4) at the second end of the adapter 324 (e.g., an adapter from a next or adjacent perforation gun). In this way, a ground may be established through the perforation gun, and from perforation gun to perforation gun, for instance, based on grounding the various metal bodies of the adjacent and contacting components as described herein.

The first detonator electrical connecter 340 may electrically connect with the first downhole component 328. For example, a mating contact pad (or other electrical connecter) of the first downhole component 328 may connect to the first detonator electrical connecter 340 for facilitating transmitting electrical signals therethrough. For example, the detonator module 326 may receive one or more electrical control signals from the first downhole component 328 to the detonator module 326. The electrical control signal may be generated by the first downhole component 328 or may otherwise be transmitted or relayed via the first downhole component 328. The electrical control signal may instruct, arm, or operate the detonator module 326 to fire the perforation gun 312 by detonating the shaped charges 336.

For instance, as shown in FIG. 3-3, the detonator module 326 may be equipped with a detonator switch 338 which may be housed within the detonator housing 327, and may be electrically connected to the first detonator electrical connecter 340 and/or the second detonator electrical connecter 342. The detonator switch 338 may be addressable via a unique identifier for indicating or addressing an electrical control signal as intended for the detonator switch 338. The detonator switch 338 may be implemented via a processor, power source, and/or any other electronic components and/or circuitry. The detonator switch 338 may be coupled to the detonator charge 339 for activating, lighting, or otherwise causing the detonator charge 339 to ignite. In one particular embodiment, the detonator switch 338 may receive control signals which may indicate for the detonator switch 338 to cause the detonator module 326 to operate in an armed mode or a disarmed mode. When in the armed mode, a voltage/current applied by surface equipment may cause the detonator charge 339 to ignite or fire. When in the disarmed mode, the circuitry of the detonator module 326 may protect or isolate the detonator charge 339 from the voltage event, and voltage/current applied from the surface may pass through to other downhole equipment (e.g., to other perforations guns). In this way, the perforation gun 312 may be selectively fired by receiving an electrical control signal specifically addressed for the detonator switch 338.

In some embodiments, the detonator module 326 may receive one or more control signals from the first downhole component 328 that are not addressed or intended for the detonator switch 338 and/or do not instruct the detonator switch 338 to fire the perforation gun 312. For example, the detonator module 326 may receive an electrical control signal from the first downhole component 328 intended for the second downhole component 330 or one or more downhole components further down the line from the second downhole component 330. Accordingly, the control signal may be transmitted or relayed through the perforation gun 312 to the second downhole component 330. For example, the first detonator electrical connecter 340 and the second detonator electrical connecter 342 may be electrically connected, for passing electrical signals therethrough. For example, the first detonator electrical connecter 340 and the second detonator electrical connecter 342 may be directly connected (e.g., with a wire, trace, circuit, or other direct connection) and/or the detonator switch 338 may facilitate the connection therebetween. In this way the various electrical connecters, conductors, etc. of the perforation gun 312 may facilitate electronic communication with the perforation gun 312 as well electronic communication through the perforation gun 312 to one or more other downhole components.

The various (e.g., electrical and ballistic) connections between the various components of the perforation gun 312 may facilitate a modular assembly of the perforation gun 312. For example, as mentioned, the detonator module 326 may be separate, modular, and/or distinct from the loading tube 322. For example, the detonator module 326 and the loading tube 322 may be separate components which may be independently insertable into the carrier tube 320. This may be in contrast to some conventional perforation guns in which the loading tube includes various detonating components positioned, housed, or included as part of the loading tube (e.g., an addressable switch, a detonator charge, etc.) rather than being modularly implemented. The detonator module 326 and the loading tube 322 being modular may facilitate manufacturing, transporting, handling, etc. the loading tube 322 without it being armed, which in some cases can be dictated by regulation such as by the department of transportation (DOT). The perforation gun 312 may be assembled and armed at a wellsite in an efficient and simple manner by inserting the detonator module 326 and the loading tube 322 into the carrier tube 320, by which the necessary electrical and ballistic connections are made. In contrast, conventional techniques in which the detonating components are integral with and/or a part of the loading tube 322 may require the detonating charge to be a separate component which must be inserted into and connected to the detonating components of the loading tube, for example, prior to inserting the loading tube into the carrier tube, requiring extra assembly steps, wire management, and introducing potential for errors.

Additionally, the loading tube 322 being fixed to the adapter 324 may provide further simplicity, efficiency of assembly, and reliability for the perforation gun 312. For example, the loading tube 322 and adapter 324 may be assembled with the carrier tube 320 together as a single step or process. In contrast, some conventional techniques may employ an independent and/or separate adapter, which must be assembled with the carrier tube 320 separate from the loading tube 322. Further, the fixed nature of the loading tube 322 with the adapter 324 allows for electrically connecting the loading tube electrical connecter 344 to the adapter electrical connecter 346 with a direct, hard-wired connection. This connection being hard wired reduces the components and complexity needed for electrically connecting the loading tube 322 and the adapter 324 which provides simplicity and reliability in addition to ease of assembly.

The perforation gun 312 as described herein having the detonator module 326, the loading tube 322, and the adapter 324 may electrically interconnect to facilitate an electrical connection across or through the perforation gun 312, as well as to facilitate electrically connecting the perforation gun 312 to one or more other downhole components. As an example, consider a scenario in which the first downhole component 328 is a top sub or control sub for controlling a string of several perforation guns, and accordingly the second downhole component 330 is an additional perforation gun. The detonator module 326 may electrically connect to the top sub via the first detonator electrical connecter 340, and in this way may receive one or more control signals addressed for the perforation gun 312 and/or for other perforation guns. The detonator switch 338 may be connected to the first detonator electrical connecter 340 for receiving the control signals, for example, in order to fire the perforation gun 312 by detonating the detonator charge 339, or otherwise for transmitting down the line to other perforation guns. The second detonator electrical connecter 342 may be electrically connected to the first detonator electrical connecter 342 and/or the detonator switch 338 for transmitting and/or relaying one or more electrical signals from the detonator module 326. For instance, the second detonator electrical connecter 342 may be electrically coupled to the loading tube electrical connecter 344, which may in turn be connected via the conductor 348 to the adapter electrical connecter 346. The adapter electrical connecter 346 may be electrically coupled to the additional perforation gun, for example, by connecting to a first detonator electrical connecter of a detonator module of the additional perforation gun. This additional perforation gun may be implemented in the same manner as the perforation gun 312, which may connect to another perforation gun, and so on. In this way, several instances of the assembly of the perforation gun 312 may be implemented in succession and may be electrically coupled via the various electrical connections described herein. In this way, electrical control signals may be transmitted through any number of successive perforation guns and received at a specific perforation gun for which a control signal is addressed or intended.

FIG. 4 is a side schematic view of an adapter 424, according to at least one embodiment of the present disclosure. The adapter 424, as described herein, may facilitate connecting two downhole components, such as connecting a first downhole component 481 to a second downhole component 482. For example, the first downhole component 481 and/or the second downhole component 482 may be a tubular component, such as a section of drill pipe, a carrier tube of a perforation gun, a top or control sub for a string of perforation guns, etc. In some embodiments, as described herein, the adapter 424 may be connected to a loading tube (e.g., on one side of the adapter) for positioning the loading tube within one of the first downhole component 481 or the second downhole component 482, or else may be implemented without any components (e.g., loading tube) attached thereto, such as a standalone adapter. For example, the first downhole component 481 may be a perforation gun having a loading tube positioned therein, and the loading tube may be fixed to the adapter 424 as described herein.

The adapter 424 may connect to the first downhole component 481 and the second downhole component 482 via a threaded connection. For example, the adapter 424, as well as the first downhole component 481 and the second downhole component 482, may include threads 484. The threads 484 may be straight threads. In this way, the first downhole component 481 may thread on to the adapter 424 from a first side of the adapter 424, and the second downhole component 482 may thread onto the adapter 424 from a second side of the adapter 424.

The adapter 424 may create a sealed connection with the first downhole component 481 and/or with the second downhole component 482. For example, the adapter 424 may include one or more seals 486 positioned around an outer diameter or outer surface of the adapter 424 which may interface with a mating surface of the first downhole component 481 and/or the second downhole component 482. The seal(s) 486 may provide a pressure and/or fluid seal to prevent pressure and/or fluid from flowing past the adapter 424, for example, from the first downhole component 481, the second downhole component 482, or from an annular space 487 between a wellbore and each of the first downhole component 481 and the second downhole component 482.

The adapter 424 may be an internal adapter 424, and may be positioned entirely internal to the first downhole component 481 and the second downhole component 482. For example, no part of the adapter 424 may extend radially outward between the first downhole component 481 and the second downhole component 482 such that no part of the adapter 424 is exposed to the annular space 487 of the wellbore. For instance, the first downhole component 481 and the second downhole component 482 may each include a shoulder 488 which may contact, abut, and/or shoulder against one another. In this way, the shoulder 488 may be an external shoulder, and the adapter may not shoulder against the first downhole component 481 or the second downhole component 482 with an external shoulder. The adapter 424 being entirely internal in this way may save on longitudinal length in making a connection between the first downhole component 481 and the second downhole component 482. For example, were a portion of the adapter 424 to be positioned at the shoulder 488 between the first downhole component 481 and the second downhole component 482, the longitudinal length of a tool string in which these components are implemented would be increased, especially when considering implementations including multiple connections made with multiple adapters 424. A shorter overall longitudinal length of a tool string may facilitate conveying the tool string into and/or out of a wellbore.

In accordance with the internal nature of the adapter 424, in some embodiments, the first downhole component 481 may include an internal shoulder 489 which may be positioned at an internal location (e.g., an inner diameter) of the first downhole component 481. The adapter 424 may contact, abut, and/or shoulder against the internal shoulder 489 such that the adapter 424 may be seated, snugged, and/or tightened adequately against the adapter 424. In some embodiments, the second downhole component 482 may not include an internal shoulder in this manner, for example, such that the adapter 424 may not seat or tighten against the second downhole component 482. Rather, the second downhole component 482 may be tightened, snugged, and/or shouldered against the first downhole component 481 at the shoulder 488.

The shouldering of the first downhole component 481 and the second downhole component 482 against one another may provide strength and rigidity to the connection of these two components, and to a tool string to which these components are included. For example, by shouldering against each other, forces, bending moments, stresses, etc. may be effectively transmitted and/or spread out among the (e.g., tubulars of the) first downhole component 481 and the second downhole component 482 such that these forces, bending movements, stresses, etc. are not carried by the adapter 424 and/or the threads 484. For example, bending a tool string (e.g., from horizontal) through a dogleg of a wellbore may impart bending moments along the length of the tool string, and the shouldered connection as described may facilitate effectively transmitting the bending moment such that the tool string is not damaged. In this way, it may be beneficial that the adapter 424 facilitate this shouldered connection of the first downhole component 481 to the second downhole component 482 at the shoulder 488.

The adapter 424 being an internal adapter, as well as shouldering against the first downhole component 481 and not the second downhole component 482, may be beneficial in that such a configuration may reduce a tolerance stack up of the manufacturing of these various components to form this connection. For example, because the adapter 424 shoulders against the first downhole component 481 at the shoulder 489 and not the second downhole component 482 and because the first downhole component 481 and the second downhole component 482 shoulder against each other at the shoulder 488 rather than against the adapter 424, the tolerances required to manufacture these parts may be much more flexible, wider, and/or more forgiving. In contrast, were both the first downhole component 481 and the second downhole component 482 to each include a (e.g., internal) shoulder 489 against which the adapter 424 would shoulder (e.g., internally), and/or were the adapter 424 to shoulder (e.g., externally) against both the first downhole component 481 and the second downhole component 482 at the shoulder 488, the tolerances required to facilitate each of these shouldered interfaces while achieving a tight, accurate connection would be much tighter, presenting challenges for manufacturing these various components.

FIG. 5-1 is an end view of a first end 565 of an adapter 524, FIG. 5-2 is a side cross-sectional view of the adapter 524, and FIG. 5-3 is an end view of a second end 566 of the adapter 524, according to at least one embodiment of the present disclosure. The adapter 524 may include one or more of the features and/or functionalities of the adapters as described herein. For example, the adapter 524 may facilitate connecting two downhole tubular components.

The adapter 524 may include a first adapter electrical connecter 546-1 at the first end 565 and a second adapter electrical connecter 546-2 at the second end 566. The first adapter electrical connecter 546-1 and the second adapter electrical connecter 546-2 may be implemented as electrical contact pads on PCBs and/or may be configured in accordance with any of the electrical connecters as described herein. In this way, the adapter 524, in addition to facilitating a physical connection of two downhole components, may provide an electrical connection between the two downhole components via the first adapter electrical connecter 546-1 and the second adapter electrical connecter 546-2. For example, a conductor 548 may traverse the adapter 524 and may connect the first adapter electrical connecter 546-1 to the second adapter electrical connecter 546-2.

The conductor 548 may be a wire conductor and may pass through an inner bore 568 of the adapter 524. The inner bore 568 may include a seal 569 as described herein for sealing the inner bore 568 against the conductor 548. The inner bore 568 may be filled with a sealant 570, for example, to support and electrically insulate the conductor 548 within the adapter 524 as well as to provide at least some pressure and/or fluid sealing function. In some embodiments, the conductor 548 may be a solid core wire conductor, and may not have any jacket or insulation at, passing through, and/or after the seal 569, but may include a jacket 580 or insulation up to and/or abutting the seal 569 as described herein. For instance, a conductor core 585 may interface with the seal 569 and may pass through the seal 569 and the remainder of the inner bore 568. In this way, the inner bore 568 may be sealed from pressure and/or fluid, but may facilitate an electrical connection traversing a pressure and/or fluid seal formed by the adapter 524 with a connected tubular component. In some embodiments, at the surface of the first adapter electrical connecter 546-1 within the inner bore 568, the conductor 548 contacts an electrical contact, which may be routed through the first adapter electrical connecter 546-1 (e.g., the PCB) and routed to the contact pad on an opposite side of the first adapter electrical connecter 546-1 which is, in turn, in electrical communication with, for example, a conductor extending along a longitudinal length of a loading tube. Similarly, at the surface of the second adapter electrical connecter 546-2 within the inner bore 568, the conductor 548 contacts an electrical contact, which may be routed through the second adapter electrical connecter 546-2 (e.g., the PCB) and routed to the contact pad on an opposite side of the second adapter electrical connecter 546-2 which is, in turn, in electrical communication with, for example, a first detonator electrical connecter.

The adapter 524 may being implemented with two electrical connecters in this way may facilitate forming a detachable, removable, and/or non-permanent electrical connection on both sides of the adapter 524. For example, a loading tube may not be fixed to the adapter 524 as described herein, but rather, the adapter 524 may be modular and/or independent from one or more adjacent components such that the adapter 524 may be assembled with these one or more adjacent components and electrically connected thereto. For example, the adapter 524 may be assembled adjacent a loading tube and may electrically connect to the loading tube. In accordance with at least one embodiment of the present disclosure, the adapter 524 may be assembled to connect a carrier tube of a perforation gun to a top sub or control sub for a string of perforation guns. For instance, the adapter 524 may be positioned between adjacent and between a detonator module of a (e.g., first and/or most uphole) perforation gun and a top sub to electrically connect to the detonator module to the top sub. In this way, the adapter 524 may be implemented for forming electrical connections on both sides of the adapter 524.

INDUSTRIAL APPLICABILITY

The following description from ¶¶ [0089]–[0130] includes various embodiments that, where feasible, may be combined in any permutation. For example, the embodiment of ¶ [0089] may be combined with any or all embodiments of the following paragraphs. Embodiments that describe acts of a method may be combined with embodiments that describe, for example, systems and/or devices. Any permutation of the following paragraphs is considered to be hereby disclosed for the purposes of providing “unambiguously derivable support” for any claim amendment based on the following paragraphs. Furthermore, the following paragraphs provide support such that any combination of the following paragraphs would not create an "intermediate generalization."

In some embodiments, a device for perforating a wellbore includes a loading tube having a first end and a second end and configured to house one or more shaped charges, the loading tube being positionable within a carrier tube, an adapter configured to connect to the carrier tube and connect the carrier tube to a downhole component, wherein the loading tube is fixed to the adapter at the second end of the loading tube and at a first end of the adapter, and wherein the adapter includes an adapter electrical connecter at a second end of the adapter, a loading tube electrical connecter connected to the first end of the loading tube, and a conductor traversing the loading tube connecting the adapter electrical connecter to the loading tube electrical connecter.

In some embodiments, the conductor is hard wired to the adapter electrical connecter and to the loading tube electrical connecter.

In some embodiments, the loading tube is welded to the adapter.

In some embodiments, the loading tube is integrally formed with the adapter.

In some embodiments, the loading tube electrical connecter includes a printed circuit board (PCB) and the conductor is connected to an electrical contact of the PCB.

In some embodiments, the loading tube electrical connecter is configured to contact an inner surface of the carrier tube to center the loading tube within the carrier tube.

In some embodiments, the adapter electrical connecter includes a PCB and the conductor is electrically coupled to an electrical contact of the PCB.

In some embodiments, the conductor is a solid core wire.

In some embodiments, the conductor passes through an inner bore of the adapter and the adapter includes a seal for sealing the conductor against the inner bore. In some embodiments, the conductor core is adhered to the seal.

In some embodiments, the conductor is a single wire that passes from the first end of the loading tube and through the adapter to the second end of the adapter.

In some embodiments, the conductor includes a jacket and wherein a portion of the conductor that passes through the inner bore does not include the jacket.

In some embodiments, the portion of the conductor that passes through the inner bore is a bare conductor.

In some embodiments, the inner bore is filled with a sealant.

In some embodiments, the sealant is epoxy.

In some embodiments, an adhesive is between the seal and the conductor.

In some embodiments, the adapter includes a seal for forming a pressure and fluid seal with the carrier tube.

In some embodiments, the device further includes a detonator cord traversing the loading tube.

In some embodiments, the device further includes a detonator tab extending from the loading tube at the first end of the loading tube, wherein the detonator cord extends from the second end of the loading tube supported by the detonator tab.

In some embodiments, the detonator tab is positionable within a detonator channel of a detonator module separate from the loading tube, wherein the detonator tab is oriented to position the detonator cord adjacent a detonator charge of the detonator module in the detonator channel.

In some embodiments, the loading tube does not include a detonator for detonating the one or more shaped charges.

In some embodiments, a detonator module for detonating shaped charges in a downhole perforation gun includes a detonator housing positionable within a carrier tube of the downhole perforation gun, a first detonator electrical connecter on a first end of the detonator housing, a second detonator electrical connecter on a second end of the detonator housing, a detonator charge positioned within the detonator housing and being at least partially exposed to an exterior of the detonator housing, an addressable switch for detonating the detonator charge based on a first electrical signal.

In some embodiments, the addressable switch is electrically connected to the first detonator electrical connecter for receiving the first electrical signal.

In some embodiments, the first detonator electrical connecter is configured to electrically connect to a first downhole component to which the carrier tube is configured to connect, for receiving the first electrical signal from the first downhole component.

In some embodiments, the detonator charge is at least partially exposed to the exterior of the detonator housing at a detonator channel of the detonator housing.

In some embodiments, the detonator channel is configured to receive a detonator tab of a loading tube separate from the detonator housing for positioning a detonator cord of the loading tube adjacent the detonator charge.

In some embodiments, the detonator module further includes a ground electrical connector at the first end of the detonator module for grounding the detonator module to a downhole component connected to a first end of the carrier tube.

In some embodiments, the second detonator electrical connecter is configured to connect to a loading tube electrical connecter of a loading tube for transmitting a second electrical signal to a second downhole component through the loading tube.

In some embodiments, the detonator module is not included as part of a loading tube having one or more shaped charges.

In some embodiments, a system for perforating a wellbore includes a carrier tube having a first end and a second end, an adapter connected to the carrier tube and having a first end and a second end, the adapter having an adapter electrical connecter at the second end, wherein the adapter is configured to connect the carrier tube at the second end of the carrier tube to a downhole component, and wherein the adapter electrical connecter is configured to electrically connect to the downhole component, a loading tube positioned within the carrier tube and having a first end and a second end, wherein the loading tube houses one or more shaped charges therein, wherein the loading tube is fixed to the adapter at the second end of the loading tube and at the first end of the adapter, and wherein the loading tube includes a loading tube electrical connecter at the first end of the loading tube, a conductor traversing the loading tube connecting the adapter electrical connecter to the loading tube electrical connecter, a detonator module positioned within the carrier tube at the first end of the loading tube, wherein the detonator module includes a detonator housing having a detonator charge positioned therein for detonating the one or more shaped charges.

In some embodiments, the detonator module is separate from the loading tube.

In some embodiments, the loading tube includes a detonator cord traversing the loading tube and a detonator tab extending from the loading tube at the first end of the loading tube, wherein the detonator cord extends from the loading tube supported by the detonator tab.

In some embodiments, the detonator tab is positioned within a detonator channel of the detonator housing and the detonator cord is positioned in the detonator channel.

In some embodiments, wherein the detonator charge is at least partially exposed to the detonator channel and the detonator cord is positioned in the detonator channel adjacent the detonator charge.

In some embodiments, the detonator module includes a first detonator electrical connecter on a first end of the detonator housing and a second detonator electrical connecter on a second end of the detonator housing.

In some embodiments, the downhole component is a second downhole component, the carrier tube is configured to connect to a first downhole component at the first end of the carrier tube, and the first detonator electrical connecter is configured to electrically connect to the first downhole component for receiving a first electrical signal to detonate the detonator charge.

In some embodiments, the detonator module includes an addressable switch connected to the first detonator electrical connecter for receiving the first electrical signal and for detonating the detonator charge.

In some embodiments, the second detonator electrical connecter is electrically connected to the loading tube electrical connecter for transmitting a second electrical signal to the second downhole component through the conductor.

In some embodiments, the detonator module is configured to receive the second electrical signal from the first downhole component via the first detonator electrical connecter.

In some embodiments, the adapter is configured to connect to the carrier tube and to the second downhole component internal to both the carrier tube and the second downhole component.

In some embodiments, the adapter is configured to connect to the carrier tube and to the second downhole component such that the carrier tube and the second downhole component shoulder against each other.

In some embodiments, the carrier tube and the second downhole component do not shoulder to the adapter with an external shoulder.

In some embodiments, the adapter shoulders to the carrier tube with an internal shoulder.

The embodiments described herein have been primarily described with reference to wellbore drilling operations; the embodiments described herein may be used in applications other than the drilling of a wellbore. For example, embodiments according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, embodiments of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous embodiment-specific decisions will be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing or process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements. Additionally, as used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.