US20200018139A1 - Autonomous perforating drone - Google Patents
Autonomous perforating drone Download PDFInfo
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- US20200018139A1 US20200018139A1 US16/542,890 US201916542890A US2020018139A1 US 20200018139 A1 US20200018139 A1 US 20200018139A1 US 201916542890 A US201916542890 A US 201916542890A US 2020018139 A1 US2020018139 A1 US 2020018139A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/11—Perforators; Permeators
- E21B43/116—Gun or shaped-charge perforators
- E21B43/1185—Ignition systems
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
- E21B23/08—Introducing or running tools by fluid pressure, e.g. through-the-flow-line tool systems
- E21B23/10—Tools specially adapted therefor
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/02—Surface sealing or packing
- E21B33/03—Well heads; Setting-up thereof
- E21B33/068—Well heads; Setting-up thereof having provision for introducing objects or fluids into, or removing objects from, wells
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/11—Perforators; Permeators
- E21B43/116—Gun or shaped-charge perforators
- E21B43/117—Shaped-charge perforators
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/11—Perforators; Permeators
- E21B43/119—Details, e.g. for locating perforating place or direction
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/09—Locating or determining the position of objects in boreholes or wells, e.g. the position of an extending arm; Identifying the free or blocked portions of pipes
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- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
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Abstract
Description
- This application claims priority to U.S. patent application Ser. No. 16/537,720, filed Aug. 12, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/831,215, filed Apr. 9, 2019 and U.S. Provisional Patent Application No. 62/823,737, filed Mar. 26, 2019, to which this application also claims the benefit, and to U.S. Provisional Application No. 62/720,638, filed Aug. 21, 2018. This application claims priority to U.S. patent application Ser. No. 16/455,816, filed Jun. 28, 2019, which claims priority to U.S. patent application Ser. No. 16/272,326 filed Feb. 11, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/780,427 filed Dec. 17, 2018, to which this application also claims the benefit, and U.S. Provisional Patent Application No. 62/699,484 filed Jul. 17, 2018. This application claims priority to U.S. application Ser. No. 16/451,440, filed Jun. 25, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/842,329, filed May 2, 2019, to which this application also claims the benefit. This application claims priority to International Patent Application No. PCT/EP2019/066919, filed Jun. 25, 2019. This application claims the benefit of U.S. Provisional Patent Application No. 62/816,649, filed Mar. 11, 2019. This application claims priority to International Patent Application No. PCT/IB2019/000526, filed Apr. 12, 2019, which claims priority to International Patent Application No. PCT/IB2019/000537, filed Mar. 18, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/678,636 filed May 31, 2018. This application claims priority to International Patent Application No. PCT/IB2019/000530 filed Mar. 29, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/690,314 filed Jun. 26, 2018. This application claims the benefit of U.S. Provisional Patent Application No. 62/765,185 filed Aug. 16, 2018. This application claims priority to U.S. patent application Ser. No. 16/272,326 filed Feb. 11, 2019, which claims the benefit of U.S. Provisional Patent Application No. 62/780,427 filed Dec. 17, 2018 and U.S. Provisional Patent Application No. 62/699,484 filed Jul. 17, 2018. This application claims the benefit of U.S. Provisional Patent Application No. 62/823,737 filed Mar. 26, 2019. This application claims the benefit of U.S. Provisional Patent Application No. 62/827,468 filed Apr. 1, 2019. This application claims the benefit of U.S. Provisional Patent Application No. 62/831,215 filed Apr. 9, 2019. The entire contents of each application listed above are incorporated herein by reference.
- Hydraulic Fracturing (or, “fracking”) is a commonly-used method for extracting oil and gas from geological formations (i.e., “hydrocarbon bearing formations”) such as shale and tight-rock formations. Fracking typically involves, among other things, drilling a wellbore into a hydrocarbon bearing formation; installing casing(s) and tubing; deploying a perforating gun including shaped explosive charges in the wellbore via a wireline or other methods; positioning the perforating gun within the wellbore at a desired area; perforating the wellbore and the hydrocarbon formation by detonating the shaped charges; pumping high hydraulic pressure fracking fluid into the wellbore to force open perforations, cracks, and imperfections in the hydrocarbon formation; delivering a proppant material (such as sand or other hard, granular materials) into the hydrocarbon formation to hold open the perforations, fractures, and cracks (giving the tight-rock formation permeability) through which hydrocarbons flow out of the hydrocarbon formation; and, collecting the liberated hydrocarbons via the wellbore.
- Perforating the wellbore and the hydrocarbon formations is typically done using one or more perforating guns. For example, as shown in
FIG. 1 , a conventionalperforating gun string 1100 may have two or moreperforating guns 1110. Each perforatinggun 1110 may have a substantiallycylindrical gun barrel 1120 housing acharge carrier 1130 including, among other things, one moreshaped charges 1140, a detonatingcord 1150 for detonating theshaped charges 1140, and aconductive line 1160 for relaying an electrical signal between connected perforatingguns 1110. - Shaped
charges 1140 in the perforatinggun 1110 are typically detonated in a “top-fire” sequence from a topmost shaped charge 1141 to a bottommost shapedcharge 1142. For purposes of this disclosure, “topmost” means furthest “upstream,” or towards the well surface, and “bottommost” means furthest “downstream,” or further from the surface within the well. The top-fire sequence is initiated by adetonator 1145 positioned nearest the topmost shaped charge 1141. The top-fire sequence may be problematic for any perforating gun or wellbore tool that is detonated while traveling at high speed, because the velocity of the tool and the wellbore fluid combined with the force from detonating a topmost explosive charge may separate and scatter different portions of the tool. This may decrease accuracy in perforating at particular locations, cause failure of explosive charges or other components, result in greater amounts of debris, and the like. In addition, it is generally more favorable for the deployment and physical conveyance for pump down operations of the wellbore tool if most of the weight of the tool (i.e., the detonator and associated control components) is at the front (downstream end) of the tool in relation to its direction of movement. -
FIG. 1B shows a cross-sectional view of a wellbore and wellhead according to the prior art use of awireline cable 2012 to place drones in awellbore 2016. In oil and gas wells, thewellbore 2016, as illustrated inFIG. 1B is a narrow shaft drilled in the ground, vertically and/or horizontally deviated. Awellbore 2016 can include a substantially vertical portion as well as a substantially horizontal portion and a typical wellbore may be over a mile in depth (e.g., the vertical portion) and several miles in length (e.g., the horizontal portion). Thewellbore 2016 is usually fitted with a wellbore casing that includes multiple segments (e.g., about 40-foot segments) that are connected to one another by couplers. A coupler (e.g., a collar), may connect two sections of wellbore casing. - In the oil and gas industry, the
wireline cable 2012, electric line or e-line are cabling technology used to lower and retrieve equipment or measurement devices into and out of thewellbore 2016 of an oil or gas well for the purpose of delivering an explosive charge, evaluation of thewellbore 2016 or other well-related tasks. Other methods include tubing conveyed (i.e., TCP for perforating) slickline or coil tubing conveyance. A speed of unwinding thewireline cable 2012 and winding thewireline cable 2012 back up is limited based on a speed of thewireline equipment 2062 and forces on thewireline cable 2012 itself (e.g., friction within the well). Because of these limitations, it typically can take several hours for awireline cable 2012 and atoolstring 2031 to be lowered into a well and another several hours for thewireline cable 2012 to be wound back up and the expended toolstring retrieved. Thewireline equipment 2062 feedswireline 2012 throughwellhead 2060. When detonating explosives, thewireline cable 2012 will be used to position thetoolstring 2031 of perforatingguns 2018 containing the explosives into thewellbore 2016. After the explosives are detonated, thewireline cable 2012 will have to be extracted or retrieved from the well. - Wireline cables and TCP systems have other limitations such as becoming damaged after multiple uses in the wellbore due to, among other issues, friction associated with the wireline cable rubbing against the sides of the wellbore. Location within the wellbore is a simple function of the length of wireline cable that has been sent into the well. Thus, the use of wireline may be a critical and very useful component in the oil and gas industry yet also presents significant engineering challenges and is typically quite time consuming. It would therefore be desirable to provide a system that can minimize or even eliminate the use of wireline cables for activity within a wellbore while still enabling the position of the downhole equipment, e.g., the
toolstring 2031, to be monitored. - During many critical operations utilizing equipment disposed in a wellbore, it is important to know the location and depth of the equipment in the wellbore at a particular time. When utilizing a wireline cable for placement and potential retrieval of equipment, the location of the equipment within the well is known or, at least, may be estimated depending upon how much of the wireline cable has been fed into the wellbore. Similarly, the speed of the equipment within the wellbore is determined by the speed at which the wireline cable is fed into the wellbore. As is the case for a
toolstring 2031 attached to a wireline, determining depth, location and orientation of atoolstring 2031 within awellbore 2016 is typically a prerequisite for proper functioning. - One known means of locating a
toolstring 2031, whether tethered or untethered, within a wellbore involves a casing collar locator (“CCL”) or similar arrangement, which utilizes a passive system of magnets and coils to detect increased thickness/mass in a wellbore casing 1580 (FIG. 7 ) at portions where coupling collars 1590 (FIG. 7 ) connect two sections ofwellbore casing 1582, 1584 (FIG. 7 ). Atoolstring 2031 equipped with a CCL may be moved through a portion of thewellbore casing 1580 having thecollar 1590. The increased wellbore wall thickness/mass thecollar 1590 results in a distortion of the magnetic field (flux) around the CCL magnet. This magnetic field distortion, in turn, results in a small current being induced in a coil; this induced current is detected by a processor/onboard computer which is part of the CCL. In a typical embodiment of known CCL, the computer ‘counts’ the number ofcoupling collars 1590 detected and calculates a location along thewellbore 2016 based on the running count. - Another known means of locating a
toolstring 2031 within awellbore 2016 involves tags attached at known locations along thewellbore casing 1580. The tags, e.g., radio frequency identification (“RFID”) tags, may be attached on or adjacent to casing collars but placement unrelated to casing collars is also an option. Electronics for detecting the tags are integrated with thetoolstring 2031 and the onboard computer may ‘count’ the tags that have been passed. Alternatively, each tag attached to a portion of the wellbore may be uniquely identified. The detecting electronics may be configured to detect the unique tag identifier and pass this information along to the computer, which can then determine current location of thetoolstring 2031 along thewellbore 2016. - Similar operations and challenges may be encountered with downhole delivery, deployment, and/or initiation of a variety of wellbore tools besides perforating guns. For example, a wellbore tool may be a puncher gun, logging tool, jet cutter, plug, frac plug, bridge plug, setting tool, self-setting bridge plug, self-setting frac plug, mapping/positioning/orientating tool, bailer/dump bailer tool, or other ballistic tool. For purposes of this disclosure, a wellbore tool is any such tool, listed or otherwise, that is delivered, deployed, or initiated in a wellbore, and the disclosed exemplary embodiments are not limited to any particular wellbore tool.
- Accordingly, current wellbore operations and system(s) require substantial amounts of onsite personnel and equipment. Even with large gun strings, a substantial amount of time, equipment, and labor may be required to deploy the perforating gun or wellbore tool string, position the perforating gun or wellbore tool string at the desired location(s), and retrieve the fired perforating gun assemblies post perforating. Further, current perforating devices and systems may be made from materials that remain in the wellbore after detonation of the shaped charges and leave a large amount of debris that must either be removed from the wellbore or left within. Accordingly, devices, systems, and methods that may reduce the time, equipment, labor, and debris associated with downhole operations would be beneficial.
- Knowledge of the location, depth and velocity of the toolstring in the absence of a wireline cable would be essential. The present disclosure is further associated with systems and methods of determining location along a
wellbore 2016 that do not necessarily rely on the presence of casing collars or any other standardized structural element, e.g., tags, associated with thewellbore casing 1580. - In an aspect, the disclosure relates to an autonomous perforating drone for downhole delivery of one or more wellbore tools. The autonomous perforating drone may comprise a perforating assembly section including at least one aperture configured for receiving a shaped charge; a control module section positioned upstream of the perforating assembly section relative to an orientation of the drone when deployed in the wellbore, the control module section including a hollow interior portion; a ballistic channel open to and extending from the hollow interior portion to the at least one aperture in the perforating assembly section; and, a control module positioned within the hollow interior portion of the control module section. The control module may include a housing enclosing a donor charge within an inner area of the control module, the donor charge being positioned adjacent to the ballistic channel. A receiver booster may be positioned within the ballistic channel, at the portion of the ballistic channel that extends to the at least one aperture, such that the receiver booster may be configured to directly initiate a shaped charge received in the aperture.
- In another aspect, the disclosure relates to a method for perforating a wellbore casing or hydrocarbon formation. The method may include arming an autonomous perforating drone according to the exemplary embodiments, e.g., including a perforating assembly section including at least one shaped charge received in an aperture, wherein at least a portion of the shaped charge and the aperture extend into a body of the drone, a control module section positioned upstream of the perforating assembly section relative to an orientation of the drone when deployed in the wellbore, the control module section including a hollow interior portion, a ballistic channel open to and extending from the hollow interior portion to the at least one aperture in the perforating assembly section, and a control module positioned within the hollow interior portion of the control module section. The control module may include a housing enclosing a detonator and a donor charge, the detonator being configured for initiating the donor charge which is positioned adjacent to the ballistic channel. A receiver booster may be positioned within the ballistic channel, at the portion of the ballistic channel that extends to the at least one aperture, and a ballistic interrupt may be positioned within the ballistic channel between the donor charge and the receiver booster in a spaced apart configuration from the donor charge and the receiver booster. The ballistic interrupt may be movable between a closed state and an open state and arming the autonomous perforating drone may include moving the ballistic interrupt from the closed state to the open state. The method may further include deploying the drone into the wellbore and detonating the at least one shaped charge.
- In a further aspect, the disclosure relates to an autonomous perforating drone for downhole delivery of one or more wellbore tools, comprising: a perforating assembly section; a control module section positioned upstream of the perforating assembly section relative to an orientation of the drone when deployed in the wellbore, the control module section including a hollow interior portion; a ballistic channel open to and extending from the hollow interior portion into at least a portion of the perforating assembly section; a control module positioned within the hollow interior portion of the control module section, and a donor charge housed within the control module and substantially aligned with the ballistic channel; a receiver booster positioned at least in part within the portion of the ballistic channel within the perforating assembly section; a first plurality of shaped charges received in a first plurality of shaped charge apertures in the body portion of the drone positioned at the perforating assembly section. In the exemplary embodiment(s), the first plurality of shaped charge apertures are arranged in a first single radial plane and an initiation end of each of the first plurality of shaped charges is substantially adjacent to the receiver booster when the respective shaped charges are received in the respective shaped charge apertures, and a second plurality of shaped charges received in a second plurality of shaped charge apertures in the body portion of the drone may be positioned at the perforating assembly section, and the second plurality of shaped charge apertures are arranged in a second single radial plane. The second single radial plane is positioned upstream of the first single radial plane, and an initiation end of each of the second plurality of shaped charges is substantially adjacent to the receiver booster when the respective shaped charges are received in the respective shaped charge apertures, such that the receiver booster may be configured to directly initiate a shaped charge received in the aperture.
- For purposes of this disclosure, a “drone” is a self-contained, autonomous or semi-autonomous vehicle for downhole delivery of a wellbore tool. For purposes of this disclosure and without limitation, “autonomous” means without a physical connection or manual control and “semi-autonomous” means without a physical connection. An “autonomous perforating drone” according to some embodiments is a drone in which, e.g., shaped charges carried by the drone are detonated within the wellbore; however, as the disclosure makes clear, an “autonomous perforating drone” is not limited to a drone for downhole delivery of shaped charges and may include any known or later-developed wellbore tools consistent with this disclosure. Further, the use of the word “drone” throughout this disclosure may be used interchangeably and/or for brevity with the phrase “autonomous perforating drone” without limitation, except where the specification otherwise makes clear.
- A more particular description will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments thereof and are not therefore to be considered to be limiting of its scope, exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
-
FIG. 1A is a cross-sectional view of a perforating gun string according to the prior art; -
FIG. 1B is a cross-sectional view of a wellbore and wellhead showing the prior art use of a wireline to place drones in a wellbore; -
FIG. 2A is a side perspective view of an autonomous perforating drone according to an exemplary embodiment; -
FIG. 2B is a side view with partial cross-sectional view taken along the planes by view ‘B’ of the autonomous perforating drone according toFIG. 2A ; -
FIG. 3A is a side view with cross-sectional view of the exemplary embodiment according toFIG. 2B , with a ballistic interrupt in a closed state; -
FIG. 3B is a side view with cross-sectional view of the exemplary embodiment according toFIG. 2B , with a ballistic interrupt in an open state; -
FIG. 4 is a perspective view with an exploded, cross-sectional view of a control module section of the exemplary embodiment according toFIG. 2B ; -
FIG. 5A is a perspective view with an exploded view of a shaped charge and a fixation connector of the exemplary embodiment according toFIG. 2B ; -
FIG. 5B shows the exemplary shaped charge for use with the exemplary fixation connector according toFIG. 5A ; -
FIG. 5C shows the exemplary fixation connector according toFIG. 5A , in a first state of assembly; -
FIG. 5D shows the exemplary fixation connector according toFIG. 5A , in a second state of assembly; -
FIG. 5E shows the exemplary fixation connector according toFIG. 5A , in a third state of assembly; -
FIG. 6A is a cross-sectional, side plan view of an ultrasonic transceiver utilized in an embodiment; -
FIG. 6B is a cross-sectional, side plan view of an ultrasonic transceiver utilized in an embodiment; -
FIG. 7 is a cross-sectional plan view of a two ultrasonic transceiver based navigation system of an embodiment; -
FIG. 8 is a plan view of a navigation system of an embodiment; -
FIG. 9 is a block diagram, cross sectional view of a drone in accordance with an embodiment; -
FIG. 10A is a perspective view of an autonomous perforating drone according to an exemplary embodiment; -
FIG. 10B is a lateral cross-sectional view of the autonomous perforating drone shown inFIG. 10A ; -
FIG. 11 is a lateral cross-sectional view of an autonomous perforating drone according to an exemplary embodiment; -
FIG. 12 is a cross-sectional view of an autonomous perforating drone according to an exemplary embodiment; -
FIG. 13A is a plan view from the tip section of the exemplary autonomous perforating drone according to claim 12; -
FIG. 13B is a cross-sectional view of the autonomous perforating drone according toFIG. 12 , taken along the plane by view ‘A’ according toFIG. 13A ; -
FIG. 14A shows an exemplary shaped charge for use with the exemplary autonomous perforating drone shown inFIG. 12 ; -
FIG. 14B shows a non-cross-sectional view of the exemplary shaped charge according toFIG. 14A ; -
FIG. 15 shows a blown-up view of the shaped charges received in the exemplary perforating gun assembly section according toFIG. 12 ; -
FIG. 16 shows a perspective view of an autonomous perforating drone according to an exemplary embodiment; -
FIG. 17 shows a reverse perspective view of the autonomous perforating drone shown inFIG. 16 ; -
FIG. 18 shows a rear plan view of the autonomous perforating drone shown inFIG. 16 ; -
FIG. 19 shows a front plan view of the autonomous perforating drone shown inFIG. 16 ; -
FIG. 20 shows a partial cutaway view of the autonomous perforating drone shown in the perspective ofFIG. 17 ; -
FIG. 21 shows a side cross-sectional view taken longitudinally through the autonomous perforating drone shown inFIG. 16 ; -
FIG. 22 shows a perspective view of an exemplary control module for use with the exemplary embodiments described herein; -
FIG. 23 shows an exemplary Control Interface Unit for use with the exemplary embodiments described herein; -
FIG. 23A shows an exemplary detonator and integrated donor charge for use with the exemplary embodiments described herein; -
FIG. 24 shows a front cross-sectional view of the control module shown inFIG. 22 housing the Control Interface Unit shown inFIG. 23 ; -
FIG. 25 shows a side view of the Control Interface Unit shown inFIG. 23 ; and, -
FIG. 26 shows an exemplary arrangement of a ballistic interrupt retention mechanism according to some embodiments. - Various features, aspects, and advantages of the embodiments will become more apparent from the following detailed description, along with the accompanying figures in which like numerals represent like components throughout the figures and text. The various described features are not necessarily drawn to scale but are drawn to emphasize specific features relevant to some embodiments.
- The headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.
- This application incorporates by reference each of the following pending patent applications in their entireties: International Patent Application No. PCT/US2019/063966, filed May 29, 2019; U.S. patent application Ser. No. 16/423,230, filed May 28, 2019; U.S. Provisional Patent Application No. 62/841,382, filed May 1, 2019; U.S. Provisional Patent Application No. 62/720,638, filed Aug. 21, 2018; U.S. Provisional Patent Application No. 62/719,816, filed Aug. 20, 2018; and U.S. Provisional Patent Application No. 62/678,654, filed May 31, 2018.
- Reference will now be made in detail to various exemplary embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments.
- Turning now to
FIG. 2A andFIG. 2B , an exemplary embodiment of an autonomous perforatingdrone 100 according to this disclosure is shown. The exemplary autonomous perforatingdrone 100 is a generally (though not literally or limitingly) torpedo-shaped assembly or module with a circumferential aspect c formed about a longitudinal axis x. The autonomous perforatingdrone 100 includes atip section 195 at a front (downstream)end 101 of the autonomous perforatingdrone 100 and atail section 180 at a rear (upstream)end 102, opposite thefront end 101, of the autonomous perforatingdrone 100. A perforatingassembly section 110 and acontrol module section 130 are respectively positioned between thetail section 180 and thetip section 195. Thecontrol module section 130 is connected at afirst end 135 of thecontrol module section 130 to thetip section 195 and at asecond end 136, opposite thefirst end 135, of thecontrol module section 130 to adownstream end 111 of the perforatingassembly section 110. The perforatingassembly section 110 includes anupstream end 112 opposite thedownstream end 111 and in the exemplary embodiment shown inFIG. 2A andFIG. 2B theupstream end 112 of the perforatingassembly section 110 is connected to thetail section 180. - The
tail section 180 may include guidingfins 181 for providing radial stability as the autonomous perforatingdrone 100 is traveling through a wellbore fluid within a wellbore. In various embodiments, one or more of thetip section 195, thecontrol module section 130, the perforatingassembly section 110, and thetail section 180 may have features such as guiding fins, a curved topology, etc. for providing one or more of rotational speed, radial stability, and reduced friction to the autonomous perforatingdrone 100. - For purposes of this disclosure, each of the “tip section”, “control module section”, “perforating assembly section”, and “tail section” is defined with respect and reference to, and to aid in the description of, the position and configuration of certain structures and componentry of the exemplary embodiments of an autonomous perforating drone as described throughout this disclosure. None of the terms “tip section”, “control module section”, “perforating assembly section”, or “tail section” is limited to any particular assembly, configuration, or delineation points of, or along, an autonomous perforating drone according to this disclosure. For example, any or all of the “tip section”, “control module section”, “perforating assembly section”, and “tail section” may be integrally formed by injection molding, casting, 3D printing, 3D milling from bar stock, etc. For purposes of this disclosure, “integral” or “integrally formed” respectively means a single piece or formed as a single piece.
- Further, for purposes of this disclosure, the term “connected” generally means joined, such as by mechanical features, adhesives, welding, friction fit, or other known techniques for joining separate components, and may also mean “integrally formed” as that term is used in this disclosure, except where otherwise indicated.
- Moreover, for purposes of this disclosure, “upstream” means in a direction towards the wellbore entrance or surface and “downstream” means in a direction deeper or further into the wellbore. For example, as the autonomous perforating
drone 100 travels downstream, thetip section 195 is positioned first in the wellbore fluid, thetip section 195 being positioned downstream of thetail section 180. The autonomous perforatingdrone 100 is deployed and conveyed through the wellbore fluid via known techniques including, but not limited to, pump down conveyance. - With continuing reference to
FIG. 2A andFIG. 2B , the exemplaryperforating assembly section 110 is generally defined by a perforatingassembly section body 119 that is configured for, among other things, retaining one or moreshaped charges 113 and a detonatingcord 160 for delivery downhole in a wellbore. The perforatingassembly section 110 is generally cylindrically-shaped and is formed about the longitudinal axis x. In the exemplary embodiment shown inFIG. 2A andFIG. 2B , the perforatingassembly section 110 includes a plurality of shapedcharges 113, and eachshaped charge 113 is positioned and retained, in part, in afirst opening 115 of anaperture 114 that extends laterally through the perforatingassembly section 110 along an axis y. The aperture extends between thefirst opening 115 on afirst side 117 of the perforatingassembly section 110 and asecond opening 116 on asecond side 118, opposite thefirst side 117, of the perforatingassembly section 110. Thefirst side 117 of the perforatingassembly section 110 and thesecond side 118 of the perforatingassembly section 110 are defined separately for each of the plurality ofapertures 114, according to the respective opposing portions of the perforatingassembly section 110 through which aparticular aperture 114 passes. As described in detail with respect toFIGS. 3A, 3B, 5A, and 5C-5E , afixation assembly 200 of the exemplary embodiment shown inFIG. 2A andFIG. 2B is positioned about thesecond opening 116 of eachaperture 114 and secures the shapedcharge 113 within theaperture 114. Thefixation assembly 200 may also secure the detonatingcord 160 in place at eachshaped charge 113 along a length L of the perforatingassembly section 110, as described in detail with respect toFIGS. 5A-5E . - With reference specifically to
FIG. 2A , the exemplary autonomous perforatingdrone 100 also includes, among other things, features such as charging/programming contacts 1800 for charging a power source and/or programming onboard circuitry contained in a control module 137 (FIG. 2B ) of the autonomous perforatingdrone 100 and a ballistic interruptactuator 460 for moving a ballistic interrupt 140 (FIG. 2B ) between a closed state 143 (FIG. 3A ) and an open state 144 (FIG. 3B ) within the autonomous perforatingdrone 100. Aspect of these features are variously shown and described throughout this disclosure and in the figures, as follows. - With reference now to
FIGS. 3A and 3B , each of those figures shows, among other things, a cross-section of the exemplarycontrol module section 130 of the autonomous perforatingdrone 100 as generally described with respect toFIG. 2A andFIG. 2B . However, as explained in greater detail further below,FIG. 3A shows the exemplary autonomous perforatingdrone 100 with the ballistic interrupt 140 in aclosed state 143 andFIG. 3B shows the exemplary autonomous perforatingdrone 100′ with the ballistic interrupt in an open state 144. - In an aspect, and with reference to
FIG. 26 , at least a portion of the ballistic interrupt 140 may include adetent 3001 for seating against a correspondingprotrusion 3000 on a surface within the drone body, for example within the cavity (not numbered) in which the ballistic interrupt 140 sits. The seating contributes to maintaining a position (relative to rotation) of the ballistic interrupt 140. In addition, astop notch 3002 may extend from, for example and without limitation, a surface of the cavity and have a size and geometry configured to resist over-rotation of the ballistic interrupt 140 within the cavity, for example, when the ballistic interrupt 140 is moved between the on and off states. - With continuing reference to
FIGS. 2A-3B , and further reference toFIG. 4 , the exemplarycontrol module section 130 is generally defined by a controlmodule section body 191 and is circumferentially-shaped and formed about the longitudinal axis x. Thecontrol module section 130 defined by the controlmodule section body 191 has a profile including, among other things, alarge diameter portion 193 with a diameter d1, a reduceddiameter portion 194 with a diameter d2, atransition region 197 positioned between thelarge diameter portion 193 and the reduceddiameter portion 194, and atapered portion 196 with a diameter d3 at aposition 196′ representing any particular point along the varying-diameter taperedportion 196 at which the diameter d3 is measured. The diameter d1 of thelarge diameter portion 193 is greater than the diameter d2 of the reduceddiameter portion 194. In the exemplary embodiments shown inFIGS. 3A and 3B , the diameter d2 of the reduceddiameter portion 194 is substantially equal to a diameter d7 of the perforatingassembly section 110. - The
transition region 197 is connected to each of thelarge diameter portion 193 and the reduceddiameter portion 194 and spans a space therebetween. The presence and profile of thetransition region 197 is not limited by the disclosed embodiments and may take any shape or configuration as particular applications dictate. The taperedportion 196 is positioned and spans a gap between the large-diameter portion 194 of thecontrol module section 130 and thetip section 195, and the diameter d3 at theposition 196′ on the taperedportion 196 gradually decreases in a direction v from the large-diameter portion 194 of thecontrol module section 130 towards thetip section 195. The exemplary profile of thecontrol module section 130 shown in, e.g.,FIG. 3B helps to reduce impacts and friction on the shapedcharges 113 as the autonomous perforatingdrone large diameter portion 193 absorbs impacts against a wellbore casing and pushes wellbore fluid out and around the perforatingassembly section 110. In other embodiments, thetip section 195 may have a different profile, for example and without limitation, an arrow-like or pointed tip. - For purposes of this disclosure, each of the “
large diameter portion 193”, “reduceddiameter portion 194”, “transition region 197”, and “taperedportion 196” is defined with respect and reference to, and to aid in the description of, the profile of the exemplarycontrol module section 130 shown in, e.g.,FIGS. 3A and 3B . None of the terms “large diameter portion 193”, “reduceddiameter portion 194”, “transition region 197”, or “taperedportion 196” is limited to any particular assembly, configuration, or delineation points of, or along, an autonomous perforating drone according to this disclosure, nor is a control module section according to this disclosure limited to a profile including one or more diameters. For example and without limitation, thecontrol module section 130 may be cylindrically shaped with a constant diameter, or may have a non-circumferential profile. - With continuing reference specifically to
FIGS. 3A and 4 (and further shown and described with respect toFIG. 13B ), thecontrol module section 130 defined by the controlmodule section body 191 includes, among other things, a hollowinterior portion 132 and aballistic channel 141 respectively positioned within thecontrol module section 130 defined by the controlmodule section body 191. Theballistic channel 141 is open to the hollowinterior portion 132 and extends from the hollowinterior portion 132 in a direction v′ from the hollowinterior portion 132 towards the perforatingassembly section 110/tail section 180. In the exemplary embodiments shown inFIGS. 3A-4 , theballistic channel 141 is surrounded by aportion 192 of increased thickness of the controlmodule section body 191 and has a diameter d4 that is smaller than a diameter d5 of the hollowinterior portion 132. The diameter d4 of theballistic channel 141 is sized to receive areceiver booster 150 which, as shown inFIGS. 3A-4 , is positioned within theballistic channel 141, and the ballistic interrupt 140 is positioned within theballistic channel 141 in a ballistic interruptcavity 146 that is formed as an area of theballistic channel 141 with a diameter d8 which is larger than the diameter d4 of theballistic channel 141. The ballistic interrupt 140 and thereceiver booster 150 are positioned in a spaced apart relationship within theballistic channel 141 such that the ballistic interrupt 140 is nearer the hollowinterior portion 132 and thereceiver booster 150 is nearer the perforatingassembly section 110. Thereceiver booster 150 is connected to the detonatingcord 160, for example by crimping, within theballistic channel 141, and the exemplaryballistic channel 141 shown in, e.g.,FIGS. 3A-4 , is sized to receive at least a portion of the detonatingcord 160. The detonatingcord 160 extends away from thereceiver booster 150 in the direction v′ towards the perforatingassembly section 110/tail section 180, and opposite the direction v towards the ballistic interrupt 140. - In some embodiments, a set of stackable pellets may be used in conjunction with, or in place of, the
receiver booster 150 for initiating the detonatingcord 160 by ballistic force. - The
control module section 130 and the hollowinterior portion 132 are sized to receive thecontrol module 137 which is positioned within the hollowinterior portion 132 of thecontrol module section 130. Thecontrol module 137 includes ahousing 138 that defines aninner area 320 of thecontrol module 137 and encloses, for example and without limitation, adetonator 133, adonor charge 134, and acontrol assembly 131. Thecontrol module 137 and thecontrol assembly 131 are further shown and described with respect toFIG. 12 . With continuing reference toFIGS. 3A-4 , thecontrol assembly 131 may include controlling and operational components of the autonomous perforatingdrone 100, such as, without limitation, a power source/battery, sensors, depth correlation device, programmable electronic circuit, trigger circuit, detonator fuse, etc. A power source/battery may also be positioned within the hollowinterior portion 132, itself, as may other components that do not necessarily need the isolation or component assemblies within theinner area 320 of thecontrol module 137. These and other components are discussed in additional detail with respect to the operation of the autonomous perforatingdrone 100, especially inFIGS. 22-25 , with respect to the exemplary embodiments of drone shown and described with respect toFIGS. 16-21 . - The modular, i.e., self-contained, nature of the
control module 137 allows it to be removed/removable from the autonomous perforatingdrone 100 during transport, e.g., to comply with regulatory requirements, and quickly loaded into the autonomous perforatingdrone 100 at a wellsite. Theinner area 320 of thecontrol module 137 can be completely or partially hollow, or not hollow at all, depending on the layout of the control module components and the requirements for sealing thecontrol module 137. For example, in an exemplary embodiment thecontrol module 137 is pressure sealed to protect the components within thecontrol module 137 from environmental conditions both outside of and within the wellbore. In other embodiments one or more of thecontrol module 137,control module section 130, and hollowinterior portion 132 may include various known seals to protect thecontrol module 137 and the components within thecontrol module 137, components within the hollowinterior portion 132, or other components within thecontrol module section 130 generally. - According to a further aspect, an electrical selective sequence signal may be sent from, e.g., the programmable electronic circuit to the
detonator 133 to initiate the detonator when the autonomous perforatingdrone 100 reaches at least one of a threshold pressure, temperature, horizontal orientation, inclination angle, depth, distance traveled, rotational speed, and position within the wellbore. The threshold conditions may be measured by any known devices consistent with this disclosure including a temperature sensor, a pressure sensor, a positioning device as a gyroscope and/or accelerometer (for horizontal orientation, inclination angle, and rotational speed), and a correlation device such as a casing collar locator (CCL) or position determining system (for depth, distance traveled, and position within the wellbore) as discussed below with respect toFIGS. 6A-9 andFIG. 12 . The electrical selective sequence signal may include one or more of an addressing signal for activating one or more power components of thedetonator 133, an arming signal for activating a detonator firing assembly such as a trigger circuit or capacitor, and a detonating signal for detonating thedetonator 133. The threshold values and other instructions for addressing, arming, and/or detonating thedetonator 133 may be taught to the programmable electronic circuit by, for example and without limitation, a control unit at a factory or assembly location or at the surface of the wellbore prior to deploying the autonomous perforatingdrone 100 into the wellbore. In an aspect, the selective sequence signal may be one or more digital codes including or more digital codes uniquely configured for thedetonator 133 of each particular autonomous perforatingdrone 100. -
FIG. 6A is a cross-section of anultrasonic transducer 1400 that may be used in a system and method of determining location along awellbore 2016. Thetransducer 1400 may include ahousing 1410 and aconnector 1402; theconnector 1402 is the portion of thehousing 1410 allowing for connections to, e.g., the programmable electronic circuit that may generate and interpret the ultrasound signals. The key elements of thetransducer 1400 are a transmittingelement 1404 and areceiving element 1406 that are contained in thehousing 1410. In the transducer shown inFIG. 6A , the transmittingelement 1404 and the receivingelement 1406 are integrated into a singleactive element 1414. That is, theactive element 1414 is configured to both transmit an ultrasound signal and receive an ultrasound signal. Electrical leads 1408 are connected to electrodes on theactive element 1414 and convey electrical signals to/from the programmable electronic circuit. Anelectrical network 1420 may be connected between the electrical leads 1408. Optional elements of a transducer include asleeve 1412, abacking 1416 and a cover/wearplate 1422 protecting theactive element 1414. -
FIG. 6B is a cross-section of an alternative version of anultrasonic transducer 1400′ that may be used in a system and method of determining location along awellbore 2016. Thetransducer 1400′ may include ahousing 1410′ and aconnector 1402′; theconnector 1402′ is the portion of thehousing 1410′ allowing for connections to, e.g., the programmable electronic circuit that may generate and interpret the ultrasound signals. The key elements of thetransducer 1400′ are a transmittingelement 1404′ and areceiving element 1406′ that are contained in thehousing 1410′. Adelay material 1418 and anacoustic barrier 1417 are provided for improving sound transmission and receipt in the context of aseparate transmitting element 1404′ and receivingelement 1406′ apparatus. - With additional reference to
FIG. 7 , an exemplary autonomous perforatingdrone 1510 as part of anultrasonic transducer system 1500 for determining the speed of the autonomous perforatingdrone 1510 traveling down awellbore 2016 by identifying ultrasonic waveform changes is shown. As depicted inFIG. 7 , the autonomous perforatingdrone 1510 may be equipped with one or moreultrasonic transducers drone 1510 has a first transducer 1530 (also marked T1) and a second transducer 1532 (also marked T2), one at each end of the autonomous perforatingdrone 1510. The distance separating thefirst transducer 1530 from thesecond transducer 1532 is a constant and may be referred to as distance ‘Z’. Each of thefirst transducer 1530 and thesecond transducer 1532 may have atransmitting element 1404 and a receiving element 1406 (as shown inFIGS. 6A and 6B ) that sends/receives signals radially from the autonomous perforatingdrone 1510. In an embodiment, each transmittingelement 1404 and receivingelement 1406 may be disposed about an entire radius of the autonomous perforatingdrone 1510; such an arrangement permits the transmittingelement 1404 and the receivingelement 1406 respectively to send and receive signals about essentially the entire radius of the autonomous perforatingdrone 1510. - The exemplary autonomous perforating
drone 1510 shown inFIG. 7 includes the firstultrasonic transceiver 1530 and the secondultrasonic transceiver 1532. Each of the firstultrasonic transceiver 1530 and the secondultrasonic transceiver 1532 is capable of detecting alterations in the medium through which the autonomous perforatingdrone 1510 is traversing by transmitting anultrasound signal return ultrasound signal wellbore casing 1580 and other material external towellbore casing 1580 will often result in a substantial change in thereturn ultrasound signal element 1406 and conveyed to autonomous perforatingdrone 1510, e.g., by the programmable electronic circuit. - With continuing reference to
FIG. 7 , becauseT2 1532 is axially displaced fromT1 1530 along the long axis of the autonomous perforatingdrone 1510,T2 1532 passes through an anomaly in thewellbore 2016 at a different time thanT1 1530 as the autonomous perforatingdrone 1510 traverses thewellbore 2016. Put another way, assuming the existence of ananomalous point 1506 along the wellbore,T1 1530 andT2 1532 pass theanomalous point 1506 in wellbore 1070 at slightly different times. In the event thatT1 1530 andT2 1532 both register a sufficiently strong and identical, i.e., repeatable, modified return signal as a result of an anomaly at theanomalous point 1506, it is possible to determine the time difference betweenT1 1530 registering the anomaly at theanomalous point 1506 andT2 1532 registering the same anomaly. The distance Z betweenT1 1530 andT2 1532 being known, a sufficiently precise measurement of time betweenT1 1530 andT2 1532 passing a particular anomaly provides a measure of the velocity of the autonomous perforatingdrone 1510, i.e., velocity equals change in position divided by change in time. Utilizing the typically safe presumption that an anomaly is stationary, the velocity of the autonomous perforatingdrone 1510 through thewellbore 2016 is available every time the autonomous perforatingdrone 1510 passes an anomaly that returns a sufficient change in amplitude of a return signal for each ofT1 1530 andT2 1532. - The potential exists for locating
ultrasonic transceiver T1 1530 andultrasonic transceiver T2 1532 in different portions of the autonomous perforatingdrone 1510 and connecting them electrically to the programmable electronic circuit. As such, it is possible to increase the axial distance Z betweenT1 1530 andT2 1532 almost to the limit of the total length of the autonomous perforatingdrone 1510.Placing T1 1530 andT2 1532 further away from one another achieves a more precise measure of velocity and retains precision more effectively as higher drone velocities are encountered, especially where sample rates forT1 1530 andT2 1532 reach an upper limit. - In an exemplary embodiment of a
navigation system 1600 such as used in theultrasonic transducer system 1500 shown inFIG. 7 , twowire coils transceivers FIG. 8 , a signal generating andprocessing unit 1640 is attached to both ends of afirst coil 1632 wrapped around afirst core 1622 of high magnetic permeability material and asecond coil 1634 wrapped around asecond core 1624 of high magnetic permeability material. As discussed previously, although thecores coils FIG. 8 as toroidal in shape, other shapes are possible. Thefirst coil 1632 and thesecond coil 1634 of the exemplary embodiment shown inFIG. 7 andFIG. 8 are configured coplanar to one another. Since a toroidal coil defines a plane, the magnetic field established by such a coil possesses a structure related to this plane. Changes in magnetic permeability occurring coplanar to the plane of the toroidal coil will have greater effect on the coil's inductance than changes that are not coplanar. Changes in magnetic permeability in a plane perpendicular to the plane of the coil may have little to no impact on the coil's inductance value. As previously described, the exemplaryultrasonic transducer system 1500 may register the same anomaly, i.e., change in magnetic permeability, once for eachcoil coils - The
processing unit 1640 may include anoscillator circuit 1644 and acapacitor 1642. An oscillating signal is generated by theoscillator circuit 1644, and sent to the wire coils 1632, 1634. With the wire coils 1632, 1634 acting as inductors, a magnetic field is established around the wire coils 1632, 1634 when charge flows through the wire coils 1632, 1634. Insertion of thecapacitor 1642 in theprocessing unit 1640 results in constant transfer of electrons between the wire coils/inductors capacitor 1642, i.e., in a sinusoidal flow of electricity between the wire coils 1632, 1634 and thecapacitor 1642. The frequency of this sinusoidal flow will depend upon the capacitance value of thecapacitor 1642 and the magnetic field generated around the wire coils 1632, 1634, i.e., the inductance value of the wire coils 1632, 1634. The peak strength of the sinusoidal magnetic field around the wire coils 1632, 1634 will depend on the materials immediately external to the wire coils 1632, 1634. With the capacitance of thecapacitor 1642 being constant and the peak strength of the magnetic field around the wire coils 1632, 1634 being constant, the circuit will resonate at a particular frequency. That is, current in the circuit will flow in a sinusoidal manner having a frequency, referred to as a resonant frequency, and a constant peak current. - With reference to
FIG. 9 , a schematic cross-sectional view of an autonomous perforatingdrone 1700 as generally described throughout this disclosure is shown. For example, the autonomous perforatingdrone 1700 may take the form of the autonomous perforatingdrone 100 shown inFIGS. 2A-3B . For example, thebody portion 1710 of the autonomous perforatingdrone 1700 may bear one or more shaped charges. As is well-known in the art, detonation of the shaped charges is typically initiated with an electrical pulse or signal supplied to a detonator. The detonator of the autonomous perforatingdrone embodiment 1700 shown inFIG. 9 and generally with respect to the exemplary embodiments of an autonomous perforating drone as described throughout this disclosure—e.g., inFIGS. 2A-3B —may be located in thecontrol module section 130, the perforatingassembly section 110, or at a position or intersection therebetween. Thedetonator 133 may initiate the shaped charges either directly or through an intermediary structure such as a detonating cord. - As would be understood by one of ordinary skill in the art, electrical power typically supplied via the
wireline cable 2012 to wellbore tools, such as a tethered drone or typical perforating gun, would not be available to an autonomous perforating drone as described herein and shown inFIG. 9 . In order for all components of the autonomous perforatingdrone 1700 to be supplied with electrical power, apower supply 1792 may be included generally as part of the autonomous perforatingdrone 1700 in any portion such as configurations dictate. It is contemplated that thepower supply 1792 may be disposed so that it is adjacent any components of the autonomous perforatingdrone 1700 that require electrical power (such as an onboard computer 390). - The on-
board power supply 1792 for the autonomous perforatingdrone 1700 may take the form of an electrical battery; the battery may be a primary battery or a rechargeable battery. Whether thepower supply 1792 is a primary or rechargeable battery, it may be inserted into the autonomous perforatingdrone 1700 at any point during construction of the autonomous perforatingdrone 1700 or immediately prior to insertion of the autonomous perforatingdrone 1700 into thewellbore 2016. If a rechargeable battery is used, it may be beneficial to charge the battery immediately prior to insertion of the autonomous perforatingdrone 1700 into thewellbore 2016. Charge times for rechargeable batteries are typically on the order of minutes to hours. - In an embodiment, another option for the
power supply 1792 is the use of a capacitor or a supercapacitor. A capacitor is an electrical component that consists of a pair of conductors separated by a dielectric. When an electric potential is placed across the plates of a capacitor, electrical current enters the capacitor, the dielectric stops the flow from passing from one plate to the other plate and a charge builds up. The charge of a capacitor is stored as an electric field between the plates. Each capacitor is designed to have a particular capacitance (energy storage). In the event that the capacitance of a chosen capacitor is insufficient, a plurality of capacitors may be used. When a capacitor is connected to a circuit, a current will flow through the circuit in the same way as a battery. That is, when electrically connected to elements that draw a current the electrical charge stored in the capacitor will flow through the elements. Utilizing a DC/DC converter or similar converter, the voltage output by the capacitor will be converted to an applicable operating voltage for the circuit. Charge times for capacitors are on the order of minutes, seconds or even less. - A supercapacitor operates in a similar manner to a capacitor except there is no dielectric between the plates. Instead, there is an electrolyte and a thin insulator such as cardboard or paper between the plates. When a current is introduced to the supercapacitor, ions build up on either side of the insulator to generate a double layer of charge. Although the structure of supercapacitors allows only low voltages to be stored, this limitation is often more than outweighed by the very high capacitance of supercapacitors compared to standard capacitors. That is, supercapacitors are a very attractive option for low voltage/high capacitance applications as will be discussed in greater detail hereinbelow. Charge times for supercapacitors are only slightly greater than for capacitors, i.e., minutes or less.
- A battery typically charges and discharges more slowly than a capacitor due to latency associated with the chemical reaction to transfer the chemical energy into electrical energy in a battery. A capacitor is storing electrical energy on the plates so the charging and discharging rate for capacitors are dictated primarily by the conduction capabilities of the capacitors plates. Since conduction rates are typically orders of magnitude faster than chemical reaction rates, charging and discharging a capacitor is significantly faster than charging and discharging a battery. Thus, batteries provide higher energy density for storage while capacitors have more rapid charge and discharge capabilities, i.e., higher power density, and capacitors and supercapacitors may be an alternative to batteries especially in applications where rapid charge/discharge capabilities are desired.
- Thus, the on-
board power supply 1792 for the autonomous perforatingdrone 1700 may take the form of a capacitor or a supercapacitor, particularly for rapid charge and discharge capabilities. A capacitor may also be used to provide additional flexibility regarding when the power supply is inserted into the autonomous perforatingdrone 1700, particularly because the capacitor will not provide power until it is charged. Thus, shipping and handling of the autonomous perforatingdrone 1700 containing shaped charges or other explosive materials presents low risks where an uncharged capacitor is installed as thepower supply 1792. This is contrasted with shipping and handling of an autonomous perforatingdrone 1700 with a battery, which can be an inherently high risk activity and frequently requires a separate safety mechanism to prevent accidental detonation. Further, and as discussed previously, the act of charging a capacitor is very fast. Thus, the capacitor or supercapacitor being used as apower supply 1792 for the autonomous perforatingdrone 1700 can be charged immediately prior to deployment of the autonomous perforatingdrone 1700 into thewellbore 2016. - In an aspect, magnetic sensors such as Hall effect magnetic sensors or magnetometers may be used in combination with a super capacitor as a depth correlation sensor in the exemplary autonomous perforating drones described herein. Such a system may be used with a magnetic ring (e.g., a plastic with flexible magnetic tape or film secured thereto) between adjacent wellbore casings, for example, at a collar between casing ends, wherein the magnetic ring includes beacons or magnets for detection by the drone sensors. In another aspect, casing collars may be painted with high temperature paint or adhesives including magnetic material such as metal fillings, powder, or flakes.
- While the option exists to ship the autonomous perforating
drone 1700 preloaded with a rechargeable battery which has not been charged, i.e., the electrochemical potential of the rechargeable battery is zero, this option comes with some significant drawbacks. The goal must be kept in mind of assuring that no electrical charge is capable of inadvertently accessing any and all explosive materials in the autonomous perforatingdrone 1700. Electrochemical potential is often not a simple, convenient or failsafe thing to measure in a battery. It may be the case that the potential that a ‘charged’ battery may be mistaken for an ‘uncharged’ battery simply cannot be reduced sufficiently to allow for shipping the autonomous perforatingdrone 1700 with an uncharged battery. In addition, as mentioned previously, the time for charging a rechargeable battery having adequate power for the autonomous perforatingdrone 1700 could be on the order of an hour or more. Currently, fast recharging batteries of sufficient charge capacity are uneconomical for the ‘one-time-use’ or ‘several-time-use’ that would be typical for batteries used in the autonomous perforatingdrone 1700. - In an embodiment, electrical components of an exemplary autonomous perforating drone as described throughout this disclosure including the
control module 137, anoscillator circuit 1644, one ormore wire coils ultrasonic transceivers control module 137, theoscillator circuit 1644, the wire coils 1632, 1634, and theultrasonic transceivers drone 1700 preloaded with a charged or uncharged battery. The power supply that is connected to the explosive materials, i.e., the capacitor/supercapacitor, may be very quickly charged immediately prior to dropping the autonomous perforatingdrone 1700 intowellbore 2016. - In an aspect, a capacitor used as a power supply in the exemplary autonomous drones described throughout this disclosure may be charged to 30-40 Amps, and/or charged for approximately 15-40 minutes per autonomous perforating drone and provide approximately 1 hour of active power.
- As shown in the exemplary embodiment of
FIG. 3A , when thecontrol module 137 is received within the hollowinterior portion 132 of thecontrol module section 130, thedonor charge 134 is adjacent to and substantially aligned with theballistic channel 141, and aportion 139 of thecontrol module housing 138 is positioned between thedonor charge 134 and theballistic channel 141. For purposes of this disclosure, “adjacent” means next to or near, but is not limited to directly abutting and does not exclude the presence of intervening structures. Thus, when thecontrol module 137 is received within the hollowinterior portion 132 of thecontrol module section 130, the ballistic interrupt 140 within theballistic channel 141 is positioned in a spaced apart relationship between thedonor charge 134 and thereceiver booster 150. - In an aspect, the
donor charge 134 is positioned within adetonator channel 145 within thecontrol module 137, and thedetonator 133 is positioned adjacent to thedonor charge 134 within thedetonator channel 145 and substantially aligned with thedonor charge 134 along the longitudinal axis x. Thedetonator 133 may be, for example and without limitation, an explosive charge or any other device as is well known in the art for causing a detonation, ignition, or ballistic initiation. In an aspect, thedetonator 133 may be a selective detonator. For purposes of this disclosure, “selective” means that thedetonator 133 is initiated only when it receives a specific initiating signal or selective sequence signal, as discussed above, from the control module 137 (i.e., the programmable electronic circuit), e.g., to cause a capacitive discharge to a fuse of thedetonator 133. One benefit of a selective detonator is that it is radio-frequency (RF)-safe—i.e., it will not be initiated by stray RF signals in the proximity of thedetonator 133. - The
donor charge 134 is also an explosive shaped charge, but thedonor charge 134 may include, for example, an explosive material within a casing (not numbered), designed to create a directed perforating jet upon detonation, as is well known in the art. According to the exemplary configuration, detonating thedetonator 133 will cause thedonor charge 134 to detonate. In an aspect, thedonor charge 134 may be designed, for example and without limitation, to have an explosive power for contributing to breaking apart the drone upon detonation. In another aspect, thedonor charge 134 may be explosive and/or explosive/liner assembly as in a typical shaped charge but may be pressed into a plastic housing instead of contained within a metal casing. - The ballistic interrupt 140 is thus an important safety and operational feature of the autonomous perforating
drone 100. For example, in operation, when thedonor charge 134 is detonated it produces the perforating jet that pierces theportion 139 of thecontrol module housing 138 between thedonor charge 134 and theballistic channel 141, and travels into theballistic channel 141. When the ballistic interrupt 140 is in theclosed state 143 shown inFIG. 3A , it provides a physical barrier and thereby prevents the perforating jet created by thedonor charge 134 from reaching thereceiver booster 150 and thereby initiating detonation (as explained further below) of the autonomous perforatingdrone 100. Specifically, with continuing reference to the exemplary embodiment shown inFIGS. 3A and 4 , the ballistic interrupt 140 includes a through-bore 142 that extends through the ballistic interrupt 140 between afirst opening 142 a of the through-bore 142 and asecond opening 142 b of the through-bore 142. When the ballistic interrupt 140 is in theclosed state 143, the through-bore 142 is substantially perpendicular to the longitudinal axis x and the ballistic interrupt 140 otherwise prevents ballistic communication between thedonor charge 134 and thereceiver booster 150 by shielding thereceiver booster 150 from the perforating jet created by thedonor charge 134. Accordingly, the ballistic interrupt 140 in theclosed state 143 does not provide a path through which the perforating jet created by thedonor charge 134 may reach thereceiver booster 150 and thus is no longer ballistically aligned with thedonor charge 134. In a further aspect of the exemplaryclosed state 143, thefirst opening 142 a and thesecond opening 142 b of the through-bore 142 may be positioned within an area of the ballistic interruptcavity 146 at the diameter d8 which is beyond the diameter of theballistic channel 141 and may enhance the shielding effect of the ballistic interrupt 140. In another aspect, the ballistic interrupt 140 may include additional holes therethrough and/or in communication with the through-bore 142, for preventing failure or collapse of the autonomous perforatingdrone 100 due to a pressure differential across the ballistic interrupt 140. - In some embodiments, the
detonator 133 may be spaced apart from thedonor charge 134. For example, a donor charge may be positioned in theballistic channel 141 or in the through-bore 142 of the ballistic interrupt 140. In such embodiments, thedetonator 133 would provide sufficient ballistic energy to reach the spaced-apart donor charge, which may include, e.g., penetrating theportion 139 of thecontrol module housing 138 between thedetonator channel 145 and theballistic channel 141. In embodiments in which a donor charge is positioned in the through-bore 142, the ballistic energy of thedetonator 133 would be insufficient to initiate the donor charge through the ballistic interrupt 140 in theclosed state 143. Thus, the safety control provided by the ballistic interrupt 140 would not be compromised. - On the other hand, when the autonomous perforating
drone 100 is ready for arming, e.g., after passing a safety check and a function test at a wellbore site and immediately before or while being deployed into the wellbore, the ballistic interrupt 140 is moved to the open state 144 as shown inFIG. 3B . In the open state 144, the through-bore 142 is substantially parallel to the longitudinal axis x and coaxial with theballistic channel 141. The through-bore 142 in the open state 144 allows ballistic communication via the through-bore 142 between thedonor charge 134 and thereceiver booster 150 such that the perforating jet created by thedonor charge 134 may reach thereceiver booster 150, causing thereceiver booster 150 to detonate when subject to the perforating jet. Thereceiver booster 150 is generally an explosive charge or any other device, as is well known in the art, for causing an explosion, initiation, or ballistic force, including encapsulated receiver boosters and receiver boosters in a pressure sealedhousing 151. Detonation of thereceiver booster 150 initiates the detonatingcord 160 which is further connected to and configured for detonating the shapedcharges 113, as is generally known and explained in additional detail with respect toFIG. 5A . - The pressure sealed
housing 151 of thereceiver booster 150 may further extend to, or a separate pressure sealed housing may be used for, the connection between thereceiver booster 150 and the detonatingcord 160. In an aspect, the pressure sealedhousing 151 may be rated to at least 10,000 psi and, for exemplary uses, to at least between 15,000 psi and 20,000 psi to enhance waterproof capability. In another aspect, a small amount of grease may be used at a crimp connection between thereceiver booster 150 and the detonatingcord 160 to prevent water invasion into the connection. As fluid ingression could potentially desensitize the explosives in the detonatingcord 160, other techniques for sealing thereceiver booster 150 onto the detonatingcord 160, and/or sealing the detonatingcord 160, are contemplated and include, without limitation, housing thereceiver booster 150 and/or the detonatingcord 160 in a cap that may include a grommet (or the like) for passing or fitting the detonatingcord 160 therethrough, and may further include additional sealing mechanisms such as internal O-rings (or the like) for preventing fluid from seeping into the explosives at certain junctions. In addition, internal contours of the autonomous perforatingdrone 100, e.g., the configuration of theballistic channel 141, may be conformed closely to the contour(s) of thereceiver booster 150 and the detonatingcord 160, including any housings, caps, or sealing mechanisms thereon, to decrease the area through which fluid may encounter the components/connections. - In a further aspect, the
receiver booster 150 may be enlarged relative to the detonatingcord 160 to prevent an initial bend or curve in the detonatingcord 160 which may interfere with assembly of the detonatingcord 160 to thereceiver booster 150 and result in nicks or crimps in the detonatingcord 160. In still a further aspect, the detonatingcord 160 may be energetically coupled to thereceiver booster 150 by engaging a lower end of thereceiver booster 150 or being placed in a side-by-side configuration with thereceiver booster 150. - The ballistic interrupt 140 is movable between the
closed state 143 and the open state 144 using, for example, a mechanical key as part of a control system at the surface of the wellbore. With reference to the exemplary embodiment shown inFIG. 5A , the ballistic interrupt 140 includes a ballistic interruptactuator 460 that is part of or in operable connection with the ballistic interrupt 140, for example when the ballistic interrupt 140 is cylindrical and extends laterally through the autonomous perforatingdrone 100, and is received in anopening 462 in the controlmodule section body 191. The ballistic interruptactuator 460 includes akeyway 461 for receiving the mechanical key (not shown). The mechanical key may rotate thekeyway 461 using a rotational force, thereby rotating the ballistic interrupt 140 between theclosed state 143 and the open state 144 (or vice versa). In the exemplary embodiments, the ballistic interrupt 140 is substantially cylindrically-shaped or spherically shaped and is rotatable between theclosed state 143 and the open state 144 (and vice versa). The ballistic interrupt 140 including the ballistic interruptactuator 460 is further shown and described with respect toFIG. 12 . In other embodiments, the ballistic interrupt 140 may take any shape or configuration consistent with this disclosure, i.e., movable between a closed state and an open state. The ballistic interrupt 140 may also be moved by other mechanical techniques and using other configurations of a ballistic interrupt actuator and mechanical engagement or otherwise, such as a socket-nut engagement or pin-slot engagement, or may be movable via a magnetic engagement, or via a tool that extends through the controlmodule section body 191 and directly engages the ballistic interrupt 140. -
FIG. 4 shows, among other things, an exploded, cross-sectional view of thecontrol module section 130 of the exemplary autonomous perforatingdrone 100. For example, thecontrol module 137 is shown removed from thehollow interior 132 of thecontrol module section 130 and anopening 147 from theballistic channel 141 into the hollowinterior portion 132 is visible. It is through theopening 147 that a perforating jet created by thedonor charge 134 travels into theballistic channel 141 and, if the ballistic interrupt 140 is in the open state 144, through the through-bore 142, and ultimately arrives at thereceiver booster 150 to initiate the detonatingcord 160 that is attached to thereceiver booster 150. - The detonating
cord 160 extends away from thereceiver booster 150 in the direction v′ towards, e.g., the perforatingassembly section 110 and the shapedcharges 113 positioned therein. The detonatingcord 160 may be any known detonating cord that is pressure and temperature resistant to downhole conditions. Aconversion region 330 guides the detonatingcord 160 to a connecting portion 410 (FIGS. 5A, 5B, and 5E ) including a detonatingcord slot 411 of a first shapedcharge 113, i.e., the shapedcharge 113 nearest thecontrol module section 130, via a guidingslot 310 formed as a radial cutaway in theconversion region 330. Theconversion region 330 in the exemplary embodiment shown inFIG. 4 is positioned between, and is integral with, each of the perforatingassembly section 110 and thecontrol module section 130. As noted previously in this disclosure, the perforatingassembly section 110 and thecontrol module section 130 are generally defined with respect and reference to the position and configuration of certain structures and componentry and for aiding the description of an exemplary autonomous perforating drone according to this disclosure. For example, the perforatingassembly section 110 in the exemplary embodiment shown inFIG. 4 is generally the length L of the autonomous perforatingdrone 100 along which the shapedcharges 113 are positioned and thecontrol module section 130 is the length M of the autonomous perforatingdrone 100 along or within which, without limitation, control components (e.g., the control module 137) and initiation components (e.g., thedetonator 133, thedonor charge 134, the ballistic interrupt 140, and the receiver booster 150) are positioned. Theconversion region 330 in the exemplary embodiment shown inFIG. 4 joins and transitions a configuration of thecontrol module section 130 on afirst side 331 of theconversion region 330 to a configuration of the perforatingassembly section 110 on asecond side 332 of theconversion region 330. - With reference now to
FIGS. 5A-5E , a shapedcharge 400 and thefixation assembly 200 for retaining the shapedcharge 400 in the perforatingassembly section 110 according to an exemplary embodiment are shown.FIG. 5A shows a breakout of the shapedcharge 400 and a fixation connector 120 (described below) from the exemplary autonomous perforatingdrone 100 andfixation assembly 200 as shown and described with respect toFIGS. 2A-4 .FIG. 5B shows the exemplary shapedcharge 400 for use in the embodiment shown inFIG. 5A .FIGS. 5C-5E show blown-up views of theexemplary fixation assemblies 200 in various stages of assembly with the exemplary shapedcharge 400 and detonatingcord 160. - With particular reference to
FIG. 5A andFIG. 5B , the exemplary shapedcharge 400 includes, among other things, aninitiation side 401 at which the detonatingcord 160, for example, will attach to detonate the shapedcharge 400, and an encapsulatedside 402 opposite theinitiation side 401 and including acap 403 for enclosing explosive and/or kinetic materials (not shown) within acasing 404 of the shapedcharge 400, as is well known in the art. The exemplary shapedcharges 400 include acap 403 because the shapedcharges drone 100 are exposed—i.e., they are not otherwise isolated from wellbore conditions by a structure of the autonomous perforatingdrone 100. Wellbore fluids and conditions may be corrosive, excessively hot and high pressure, turbulent, and/or otherwise damaging to the shapedcharges charge casing 404. Encapsulated shaped charges are generally known for such exposed applications. However, in various embodiments consistent with this disclosure, an autonomous perforating drone may have a configuration for enclosing associated shaped charges and thereby obviating the need for encapsulated shaped charges. - Continuing with reference to
FIG. 5A andFIG. 5B , the connectingportion 410 of the exemplary shapedcharge 400 is positioned at theinitiation side 401 of the shapedcharge 400 and may be integrally formed with thecasing 404 as a projection therefrom. The exemplary connectingportion 410 shown inFIG. 5A andFIG. 5B is configured generally as a cylinder with the detonatingcord slot 411, i.e., a parabolic void, extending between abottom surface 121 of the connectingportion 410 and a detonatingcord seat 415 within the cylinder. The detonatingcord slot 411 and the detonatingcord seat 415 may be shaped complimentarily to the detonatingcord 160 or may include any configuration consistent with retaining and guiding the detonatingcord 160 betweenshaped charges 400 along the length L of the autonomous perforatingdrone 100, as described herein. - With additional reference now to
FIGS. 5C-5E , the shapedcharge 400 and the connectingportion 410 are configured and sized such that the connectingportion 410 and an external threadedportion 412 of the connectingportion 410 protrude from acentral aperture 171 of thefixation assembly 200 when the shapedcharge 400 is received in theaperture 114 through the perforatingassembly section 110. In the exemplary embodiments shown inFIGS. 5A and 5C-5E , thecentral aperture 171 defines, in part, thesecond opening 116 of theaperture 114 through the perforatingassembly section 110. This configuration provides a connection area for thefixation connector 120 to engage the connectingportion 410 of the shapedcharge 400 and clamp, compress, or otherwise secure the connectingportion 410 at thesecond opening 116, thereby securing, at least in part, the shapedcharge 400 in theaperture 114. In the exemplary embodiment shown inFIGS. 5A, 5D, and 5E , thefixation connector 120 is an annular, female connector with a threadedinner surface 420 and anannular opening 421. The threadedinner surface 420 of thefixation connector 120 is complimentary to the external threadedportion 412 of the connectingportion 410 of the shapedcharge 400, for threadingly engaging the external threadedportion 412 of the connectingportion 410 when the connectingportion 410 is received within theannular opening 421 of thefixation connector 120. Thefixation connector 120 may then be threadingly advanced along the external threadedportion 412 of the connectingportion 410 until, e.g., it reaches and begins to compress against an opposing surface or structure of thefixation assembly 200. In the exemplary embodiment shown inFIGS. 5A and 5C-5E , the opposing structure includes a plurality ofteeth 450 extending outwardly from a star-shapedplate 170 that will be further described with respect to thefixation assembly 200. However, thefixation assembly 200 is not limited by the disclosed geometries or configurations. In various embodiments (see, e.g.,FIGS. 10B-15 ), other known compression, connection, or retention devices and techniques including, without limitation, clamps, clasps, screws, nuts, ratcheting connectors, straps, bands, tape, rubber rings and the like may be used to fixate various exemplary shaped charges, in various exemplary autonomous perforating drone assemblies. Further, the mechanisms, structures, and components of a particular fixation assembly may be separate or may be integrally formed with each other and/or the perforatingassembly section body 119 as, for example, features of a single injection-molded piece. - With continuing reference to
FIGS. 5A and 5C-5E , the star-shapedplate 170 in theexemplary fixation assembly 200 is integrally formed with the perforatingassembly section body 119, as a feature thereof. For example, the star-shapedplate 170 is a generally circularly-shaped surface feature on thesecond side 118 of the perforatingassembly section body 119 with respect to, and opposite, thefirst opening 115 of acorresponding aperture 114 through the perforatingassembly section 110, with which the star-shapedplate 170 is concentrically aligned. In an aspect, the star-shapedplate 170 may be a terminus of theaperture 114. - The star-shaped
plate 170 is defined in part by anouter ring portion 174 from which a plurality offingers 172 extend radially inwardly between theouter ring portion 174 andrespective end portions 440 of eachfinger 172. Theend portions 440 are collectively positioned about thecentral aperture 171 in the star-shapedplate 170 and thereby define thecentral aperture 171. Thecentral aperture 171 extends laterally (e.g., along the axis y) through the star-shapedplate 170 between an outside of the autonomous perforatingdrone 100 and an interior (not numbered) of theaperture 114 through the perforatingassembly section 110. A plurality ofgaps 173 extend radially outwardly from thecentral aperture 171 such that thefingers 172 and thegaps 173 are alternatingly arranged about a circumference of thecentral aperture 171, thus creating the so-called “star-shaped” feature. - The
end portions 440 of some of thefingers 172 collectively include the plurality ofteeth 450 that form a compression surface for thefixation connector 120 as described further herein with respect to an exemplary practice of the autonomous perforatingdrone 100. Each of theteeth 450 is a projection that is connected to, or integral with, arespective end portion 440 and extends away from theend portion 440 at about a 90-degree angle to thefinger 172, in a direction away from the longitudinal axis x of the autonomous perforatingdrone 100. Thus, the plurality ofteeth 450 will extend along at least a portion of the connectingportion 410 of the shapedcharge 400 that protrudes from thecentral aperture 171 of the star-shapedplate 170 when the shapedcharge 400 is retained in theaperture 114 through the perforatingassembly section 110. - In an exemplary practice of the autonomous perforating
drone 100, eachshaped charge 400 may be connected to the exemplary autonomous perforatingdrone 100 by inserting the shapedcharge 400 into the correspondingaperture 114 through the perforatingassembly section 110. When the shapedcharge 400 is fully received in theaperture 114 the connectingportion 410 including the external threadedportion 412 and the detonatingcord slot 411 protrudes from thecentral aperture 171 in the star-shapedplate 170, as described. The detonatingcord 160 may then be inserted into the detonatingcord slot 411, down to the detonatingcord seat 415, and thefixation connector 120 may be threaded onto and advanced along the connectingportion 410 until it reaches the plurality ofteeth 450, against which it will compress and retain the shapedcharge 400 and the detonatingcord 160. The exemplary configuration of the plurality ofteeth 450 shown inFIGS. 5A and 5C-5E elevates thefixation connector 120 above the detonatingcord 160 within the detonatingcord slot 411 such that thefixation connector 120 may be sufficiently compressed against the plurality ofteeth 450 to secure the shapedcharge 400 without crushing the detonatingcord 160. Further, the compression is enhanced because theteeth 450 are positioned on thefingers 172 which have additional resiliency and may conform to oppose specific forces created by thefixation connector 120. - The configuration also allows the detonating
cord 160 to extend along the length L of the perforatingassembly section 110 through spaces (not numbered) created between the plurality ofteeth 450 byend portions 440 that do not includeteeth 450. In addition, the shapedcharge 400 may be oriented (e.g., turned) within theaperture 114 such that the detonatingcord slot 411 is oriented to direct the detonatingcord 160 towards a subsequent shapedcharge 400 on the perforatingassembly section 110. In the exemplary embodiment shown inFIG. 5A , the shapedcharges 400 are arranged in a helical pattern along the length L, and the detonatingcord 160 follows the helical pattern and connects to each of the shapedcharges 400. The detonatingcord 160 in the assembledfixation assembly 200 is held in sufficient contact, communication, or proximity with theinitiation end 401 of the shapedcharges 400 such that the detonatingcord 160 is energetically coupled to theinitiation end 401 of eachshaped charge 400 so as to detonate the explosive charge within thecasing 404, as is well known in the art. - While the shaped charge apertures 114 (and correspondingly, the shaped
charges 113, 400) are shown in a typical helical arrangement about the perforatingassembly section 110 in the exemplary embodiment shown inFIGS. 2A-5E , the disclosure is not so limited and it is contemplated that any arrangement of one or more shaped charges may be accommodated, within the spirit and scope of this disclosure, by the exemplary autonomous perforatingdrone 100. For example, a single shaped charge aperture or a plurality of shaped charge apertures for respectively receiving a shaped charge may be positioned at any phasing (i.e., circumferential angle) on the body portion, and a plurality of shaped charge apertures may be included, arranged, and aligned in any number of ways. For example, and without limitation, the shapedcharge apertures 114 may be arranged, with respect to the body portion, along a single longitudinal axis, within a single radial plane, in a staggered or random configuration, spaced apart along a length of the body portion, pointing in opposite directions, and the like. - In the exemplary embodiments, the autonomous perforating
drone 110 including the perforatingassembly section body 119, the controlmodule section body 191, thetip section 195, and thetail section 180 may be formed from a material that will substantially disintegrate upon detonation of the shapedcharges 113. In an exemplary embodiment, the material may be an injection-molded plastic that will substantially dissolve into a proppant when the shapedcharges 113 are detonated, and the autonomous perforatingdrone 100 may be an integral unit. In the same or other embodiments, one or more portions of the autonomous perforatingdrone 100 may be formed from a variety of techniques and/or materials including, for example and without limitation, injection molding, casting (e.g., plastic casting and resin casting), metal casting, 3D printing, and 3D milling from a solid plastic bar stock. Reference to the exemplary embodiments including injection-molded plastics is thus not limiting. Further, as noted herein, the description of particular sections and portions of an autonomous perforatingdrone 100 are for aiding the disclosure with respect and reference to the position of various components, and forming the autonomous perforatingdrone 100, for example, with one or a combination of integral and separate elements, may be done as applications dictate, without limitation based on the disclosed sections and portions of an autonomous perforatingdrone 100. - For example, the autonomous perforating
drone 100 may be formed as an integral unit, and a portion such as thetip section 195 according to this disclosure may then be removed and adapted for re-securing to the autonomous perforatingdrone 100, to allow the autonomous perforatingdrone 100 to, e.g., be transported without a detonator assembly (such as in the control module 137) according to applicable regulations. Once on site, thecontrol module 137 may be inserted into, e.g., thecontrol module section 130 according to this disclosure, and thetip section 195 re-secured thereto. Thetip section 195 may be adapted for re-securing to thecontrol module section 130 by milling, turning or injection molding complementary threaded portions, click slots or a bayonet key-turn in each, or using other techniques as known. The connection between thetip section 195 and the control module section is further shown and discussed with respect toFIG. 12 . In another aspect, thecontrol module 137 may be preassembled in thecontrol module section 130, before transport, as applicable regulations and applications allow. - An autonomous perforating
drone 100 formed according to this disclosure leaves a relatively small amount of debris in the wellbore post perforation. In some embodiments, at least a portion of the autonomous perforatingdrone 100 may be formed from plastic that is substantially depleted of other components including metals. Substantially depleted may mean, for example and without limitation, lacking entirely or including only nominal or inconsequential amounts. In some embodiments, the plastic may be combined with any other materials consistent with this disclosure. For example, the materials may include metal powders, glass beads or particles, known proppant materials, and the like that may serve as a proppant material when the shapedcharges 113 are detonated. In addition, the materials may include, for example, oil or hydrocarbon-based materials that may combust and generate pressure when one or more of thedetonator 133, thedonor charge 134, and the shapedcharges 113 are detonated, synthetic materials potentially including a fuel material and an oxidizer to generate heat and pressure by an exothermic reaction, and materials that are dissolvable in a hydraulic fracturing fluid. - In some embodiments, the exemplary autonomous perforating
drone 100 may be connected at thetail portion 180 to a wireline that extends to the surface of the wellbore. The wireline may be connected to the autonomous perforating drone by any known technique for connecting a wireline to a wellbore tool. The wireline may further assist in retrieving any components of the autonomous perforating drone, including, without limitation, a control module, data collection device, or other portions that remain in the wellbore post detonation/perforation. The remaining components may be retracted to the surface along with the wireline. - The exemplary drones described throughout this disclosure, for example and without limitation, with particular reference to
FIGS. 16-25 , may also be configured for connecting in series as a drone string. In an aspect of a drone string, a single control assembly and/or ballistic interrupt assembly may be used for every drone in the drone string and the drone string would detonate upon a single initiation. - In an exemplary operation, one or more autonomous perforating drones 100 according to the disclosed embodiments are connected to a control system at the surface of a wellbore. The autonomous perforating drones 100 may be manually connected to the control system, or loaded into, for example and without limitation, a deployment vehicle, pressure equalization chamber, or other system for deploying the autonomous perforating drones 100 into the wellbore and including an appropriate connection to the control system. The control system may perform, among other things, a safety check and function test on each autonomous perforating
drone 100. Upon a successful result from any test for safety, function, compliance, and/or otherwise, the control system or an operator may “arm” the autonomous perforatingdrone 100 by moving the ballistic interrupt 140 to an open state 144, as described. The control system may also record which autonomous perforating drones 100 have been armed and determine the order in which the respective autonomous perforating drones 100 will be deployed. The control system may communicate the order, and other instructions, to the autonomous perforatingdrone 100 via an electrical connection to thecontrol assembly 131, e.g., the programmable electronic circuit, of each autonomous perforatingdrone 100 as described. Other instructions may include, without limitation, a threshold depth at which to send a detonation signal to thedetonator 133, a time delay or other instructions for arming a trigger circuit, desired data to transmit to the wellbore surface, or other instructions that a control system may provide as discussed in United States Provisional Patent Application. Nos. 62/690,314 filed Jun. 26, 2018 and 62/765,185 filed Aug. 20, 2018, both of which are incorporated herein by reference in their entirety. - In the exemplary embodiments, the
control assembly 131 includes, without limitation, a depth correlation device, and the programmable electronic circuit is either pre-programmed, or programmed via the control system, to receive from the depth correlation device data regarding the current depth of the autonomous perforatingdrone 100 within the wellbore and send a detonation signal to thedetonator 133 when the autonomous perforatingdrone 100 reaches a predetermined depth. The depth correlation device may be, for example, an electromagnetic sensor, an ultrasonic transducer, or other known depth correlation devices consistent with this disclosure. The autonomous perforatingdrone 100 may also include a velocity sensor for measuring a current velocity of the autonomous perforatingdrone 100 within the wellbore, or the depth correlation device may include a velocity sensor or calculate a velocity based on sequential depth readings, and the programmable electronic circuit may be programmed to receive such velocity data as part of a criteria for transmitting the detonation signal. - In some embodiments, the autonomous perforating
drone 100 may work with other systems, such as radio-frequency (RF) transducers, casing collar locators (CCL), or other known systems for determining a position of a wellbore tool within the wellbore. - With reference again to the exemplary embodiments, after being deployed into the wellbore the depth correlation device measures the depth of the autonomous perforating
drone 100 within the wellbore. When the autonomous perforatingdrone 100 reaches the predetermined depth, the programmable electronic circuit sends a detonation signal to thedetonator 133, which initiates detonation of thedonor charge 134 and ultimately the shapedcharges 113, as described. The programmable electronic circuit may be in wired, wireless, or contactable electrical communication with thedetonator 133 by various known techniques, or may send the detonation signal via, or after activating, e.g., a trigger circuit or other intervening detonation component. The detonation signal may be, without limitation, a selective sequence signal, as previously discussed, that is unique to thedetonator 133 of the particular autonomous perforatingdrone 100. The selective detonation signal may provide a safety measure against accidental firing by, for example, external RF signals. - As described, the autonomous perforating
drone 100 travels through the wellbore with thetip section 195 downstream, and the detonatingcord 160 is initiated by thereceiver booster 150 at thedownstream end 111 of the perforatingassembly section 110. Accordingly, the ballistic/thermal release from the detonatingcord 160 propagates along the length L of the perforatingassembly section 110 in a direction from thedownstream end 111 of the perforatingassembly section 110 to the upstream end of the perforatingassembly section 110, and the shapedcharges 113 are correspondingly detonated (by the detonating cord 160) in a bottom-up, i.e., downstream to upstream, sequence. This bottom-up sequence for detonating the shapedcharges 113 prevents downstream shaped charges and portions of the autonomous perforatingdrone 100 from being separated and blown away from the rest of the assembly, as may happen if an upstream shaped charge is detonated while a drone is traveling at high velocity in a wellbore fluid. Accordingly, the bottom-up detonation sequence may prevent downstream shaped charges from failing to detonate or detonating at an undesired location, and leaving unexploded shaped charges and extra debris in the wellbore. - With reference now to
FIGS. 10A and 10B ,FIG. 10A shows an autonomous perforatingdrone 1200 according to an exemplary embodiment in which a plurality ofshaped charges 1240 are arranged within one or more single radial planes R around a perforatingassembly section body 1210 of the autonomous perforatingdrone 1200. Each of the shapedcharges 1240 is received and retained in a corresponding shapedcharge aperture 1213 at least in part within an interior 1214 of the perforatingassembly section body 1210.FIG. 10B is a cross-sectional view showing the arrangement of the shapedcharges 1240 and the shapedcharge apertures 1213, among other things, within theinterior 1214 of the perforatingassembly section body 1210 of the exemplary autonomous perforatingdrone 1200 shown inFIG. 10A . In particular,FIG. 10B is a lateral cross-sectional view of the perforatingassembly section body 1210 of the autonomous perforatingdrone 1200 shown inFIG. 10A taken along the radial plane R. For purposes of this disclosure, a radial plane is a plane generally containing each of a plurality of radii (e.g., shaped charges 1240) extending from a common center. The exemplary autonomous perforatingdrone 1200 shown inFIGS. 10A and 10B includes three shapedcharges 1240 arranged in the same radial plane R and spaced apart by about a 120-degree phasing around the perforatingassembly section body 1210. The type(s) of shaped charges used with an autonomous perforating drone as described throughout this disclosure are not limited and may include any shaped charges as are well-known and/or would be understood in the art and consistent with this disclosure. Exemplary embodiments of shaped charges for use with embodiments of an autonomous perforating drone and arrangement of shaped charges/shaped charge holders according to this disclosure, but not limited thereto, are shown and described with respect toFIGS. 10B-13B . -
FIG. 10B also shows a detonator orbooster 1271 positioned within theinterior 1214 of the perforatingassembly section body 1210 and adjacent to the shapedcharges 1240 such that the shapedcharges 1240 extend radially from thedetonator 1271. In an aspect, thedetonator 1271 may directly initiate detonation of the shapedcharges 1240 upon detonation of thedetonator 1271. In some embodiments, a detonation extender, such as a detonating cord or a booster device may also be secured in theinterior 1214 of the perforatingassembly section body 1210. The detonator extender may abut an end of thedetonator 1271 or may be in side-by-side contact with at least a portion of thedetonator 1271. The detonation extender may be in communication with thedetonator 1271 such that upon activation of the detonator 1271 a detonation energy from thedetonator 1271 simultaneously detonates the shaped charges in a first radial plane R and then initiates the detonation extender such that the detonation extender transfers a ballistic energy to detonate shaped charges arranged in a second, third, etc. radial plane R+1, R+2 (FIG. 12 ). - With reference now to
FIG. 11 , an exemplary autonomous perforatingdrone 1300 according to some embodiments may include a threaded connection between ashaped charge 1340 and a shapedcharge aperture 1313 in which the shapedcharge 1340 is received. For example,FIG. 11 shows a lateral cross-sectional view taken along a radial plane of abody portion 1310 of the exemplary autonomous perforatingdrone 1300, similar to the lateral cross-sectional view shown inFIG. 10B . As shown inFIG. 11 , the exemplary autonomous perforatingdrone 1300 includes three shapedcharges 1340 arranged in the same radial plane and spaced apart by about a 120-degree phasing around the perforatingassembly section body 1310. The shapedcharges 1340 are respectively received and retained in the shapedcharge apertures 1313 at least in part within an interior 1314 of the perforatingassembly section body 1310. According to an aspect, the shapedcharge apertures 1313 include aninternal thread 1320 for threadingly securing the shapedcharge 1340 therein. Theinternal thread 1320 may be a continuous thread or interrupted threads that mate or engage withcorresponding threads 1332 formed on aback wall protrusion 1330 of the shapedcharge 1340. Other aspects of a configuration of a shaped charge for use with an autonomous perforating drone as described throughout this disclosure are not limited by this disclosure and may include a shaped charge having any configuration as is well-known and/or would be understood in the art and consistent with this disclosure. For example, a shaped charge configuration in which a shaped charge casing houses one or more explosive loads and a liner atop the explosive loads for containing the explosive load(s) within the shaped charge and forming a perforating jet upon detonating the shaped charge. - In the exemplary configuration shown in
FIG. 11 , a detonator 1371 (and/or optionally, a detonating cord) is positioned within theinterior 1314 of the perforatingassembly section body 1310 and adjacent to the shapedcharges 1340 such that the shapedcharges 1340 extend radially from thedetonator 1371. In an aspect, thedetonator 1371 may directly initiate detonation of the shapedcharges 1340 upon detonation of thedetonator 1371. It is contemplated that at least one of the shapedcharge apertures 1313 may be in open communication with a hollow portion of theinterior 1314 of the perforatingassembly section body 1310 in which thedetonator 1371 and/or the detonating cord is positioned. - The arrangement of shaped charges within a single radial plane as shown in
FIGS. 10A-11 is not limited to the embodiments depicted in those figures, nor is the disclosure of such arrangements limiting. For example, any number of charges capable of fitting around a circumference of a portion of an autonomous perforating drone according to this disclosure may be arranged within a single radial plane and respectively spaced apart at any desired phasing. In another non-limiting example, shaped charges in separate radial planes may be arranged in a staggered fashion such that the shaped charges overlap along a single radial plane. In addition, one or more of a detonator, selective detonator, detonating cord, and other internal components of an autonomous perforating drone may be included and configured as particular applications consistent with this disclosure dictate. - With reference now to
FIG. 12 , a partial cross-section view of an exemplaryautonomous drone 1200 with charges arranged in a series of respective radial planes R, R+1, in accordance, at least in part, with the embodiment shown inFIG. 10A , is shown. As discussed throughout this disclosure,autonomous drone 1200 includes acontrol module section 130 positioned between and connected to each of atip section 195 and a perforatingassembly section 110. Thecontrol module section 130 in the exemplary embodiment shown inFIG. 12 is connected to thetip section 195 via complimentary engagement structures including alip 1835 extending away from afirst end 135 of thecontrol module section 130 and acorresponding lip 199 formed on thetip section 195. Thelip 1835 of thecontrol module section 130 includes atab 1835 a extending inwardly (i.e., towards axis x) and aconcave surface 1835 b positioned between and connected to each of thetab 1835 a and the controlmodule section body 191. Thelip 199 of thetip section 195 includes anotch 199 a and atongue 199 b configured respectively to receive thetab 1835 a of thelip 1835 of thecontrol module section 130 and be received against theconcave surface 1835 b of the lip of thecontrol module section 130.Tab 1835 a thereby prevents lateral movement or disengagement of thetip section 195 by engaging each of thenotch 199 a and thetongue 199 b. - In an aspect, one or both of the control module section body 191 (including the lip 1835) and the
lip 199 of thetip section 195 may be formed from a material with sufficient flexibility and resiliency to allow engagement of thelip 1835 of thecontrol module section 130 and thelip 199 of thetip section 195 to move under a force of pushing thetip section 195 and thecontrol module section 130 together, thereby bringing the respective engagement structures into position, before returning the complimentary engagement portions into their set position providing engagement as described above. In an aspect, thetip section 195 may be formed from a material such as, but not limited to, a hard rubber. In a further aspect, the material is abrasion-resistant. The separable aspect of thetip section 195 and thecontrol module section 130 may allow selective insertion of thecontrol module 137 into thehollow interior 132 of thecontrol module section 130. Other techniques and configurations for removably securing thetip section 195 to thecontrol module section 130 include, without limitation, threaded engagements, dovetail arrangements, or other techniques as are known for removably securing structures. - In another aspect, the
tip section 195 may be configured as a “frac ball” for sealing a corresponding “frac plug” downhole in the wellbore. For example, frac plugs are well known for isolating zones of a wellbore during perforation. One style of known frac plugs are configured as sealing elements with an open channel through the center of the plug such that the plug may be completely sealed by a frac ball that sets within the open channel. Sealing a zone currently undergoing perforation and fracking from downstream portions of the wellbore allows the fracking fluid to more efficiently achieve the pressures required for cracking hydrocarbon formations in the current zone because the fracking fluid does not lose pressure required to fill downstream portions of the wellbore. However, once the wellbore is ready for production, the frac balls must be drilled out of the frac plug openings to allow hydrocarbons to flow through the wellbore and to the surface. - In an aspect, the
tip section 195 of the autonomous perforating drone may be configured dimensionally for use as a frac ball and formed from one or more materials such that the frac ball tip section will not be destroyed upon detonation of the autonomous perforating drone. The frac ball tip section may be retained to thecontrol module section 130 by any known techniques including a threaded portion, clips, straps, friction fits, adhesives, retention in a cavity, or other techniques as described in or consistent with this disclosure. Upon detonation of the autonomous perforating drone, the frac ball tip section will release and travel downstream until it encounters and seals a frac plug. A drone for use with a frac ball tip section may be an autonomous perforating drone as described throughout this disclosure or may be a “dummy” drone, i.e., that does not carry perforating charges or other wellbore tools for performing a separate function in the wellbore. In either case, thecontrol module 137 of the autonomous perforating (or dummy) drone may be made from standard metal and drilled out with the frac ball/plug, and the shaped charges may be formed at least in part from zinc to reduce debris. In addition, an autonomous perforating drone incorporating a tip section as a frac ball may be used in conjunction with an autonomous drone for deploying a frac plug, such that the frac plug drone is sent downhole, sets the plug, and the frac ball drone is sent in thereafter to provide the frac ball seal and potentially perforate the wellbore casing/hydrocarbon formation with shaped charges as discussed throughout this disclosure. - Continuing with reference to
FIG. 12 , an exemplary arrangement of components in thecontrol module 137 is shown. In an aspect, thecontrol module 137 includes apower source 1792 such as a battery or a capacitor as previously discussed. Thepower source 1792 may be used to power one or more of, among other things, an onboard computer 390 (i.e., control circuit(s)),sensors 1820 such as depth or velocity sensors, among others, as previously discussed, anddetonator control electronics 1810 for, e.g., receiving and responding to selective detonation signals. Charging/programming contacts 1800 are electrically connected to one or more of, e.g., thepower source 1792 and the onboard circuitry/sensors module section body 191 for connecting to an external power/control source and respectively charging or programming components of thecontrol module 137. In an aspect, thecontacts 1800 may be a combination of various seals and electrical contacts configured for, without limitations, isolating a relay between an electrical contact on an outside of the drone and a programmable electronic circuit or a power supply. The seals and connections may include, without limitation, o-rings, gaskets, face seals, sealing tape, contact pins, shafts, surfaces extending from the drone body, and the like. - In an aspect, the components of the
control module 137 in the exemplary embodiment shown inFIG. 12 are potted inmaterial 1830 in thecontrol module 137 to further pressure-isolate the components from potentially detrimental influence of surrounding environmental conditions, such as those of the wellbore. Other pressure-isolation techniques for the components include, without limitation, covering, embedding, and/or encasing the components in an injection-molded or 3D-printed material, and the like. Exemplary materials may include, without limitation, polyethylene-, polypropylene-, and/or polyamide-compounds. - The
control module section 137, as previously discussed, further includes adetonator 133 and adonor charge 134 positioned within adetonator channel 145 of thecontrol module 137. Thedonor charge 134 is substantially aligned with aballistic channel 141 in which a ballistic interrupt 140 is positioned in a spaced apart relationship between thedonor charge 134 and areceiver booster 150. In the embodiment shown inFIG. 12 , thereceiver booster 150 extends along a length of theballistic channel 141 that is adjacent to a plurality of shapedcharges 113 arranged in respective single radial planes R, R+1 and thereby directly initiates the shapedcharges 113 upon detonation of thereceiver booster 150 in a manner as previously discussed with respect to, e.g., a detonator or a detonating cord. - The exemplary ballistic interrupt 140 is cylindrically-shaped and functions as previously described. For example, the ballistic interrupt 140 in
FIG. 12 is shown in an open state, i.e., where theautonomous drone 1200 would be considered armed in the sense that thedonor charge 134 and thereceiver booster 150 are in ballistic communication through the through-bore 142. The ballistic interrupt 140 may be movable, as previously described, between a closed state and an open state by, e.g., rotating ballistic interruptactuator 460 approximately 90 degrees in a direction a, or opposite direction, such that the through-bore 142 shown inFIG. 12 as concentric withballistic channel 141 would resultingly have a configuration perpendicular to the ballistic channel 141 (or, into the page as in the view ofFIG. 12 ), i.e., a closed state of the ballistic interrupt 140. -
FIG. 13B shows a cross-section of the exemplaryautonomous drone 1200 shown inFIG. 12 taken, according toFIG. 13A , along line A-A from thefirst end 135 of thecontrol module section 130, and without the various internal components such that the internal configuration alone, including thehollow interior 132 of thecontrol module section 130, theballistic channel 141, theopening 462 for theballistic actuator 460, and others as explained below, are illustrated. - With continuing reference to
FIG. 12 , and further reference toFIGS. 13B-15 , an exemplary shapedcharge 1240 as shown inFIG. 12 and for use in the arrangement of, e.g.,FIG. 10B , although not limited thereto or restricted for use in that embodiment, is shown. As is well known for shaped charges, generally, and applicable commonly throughout this disclosure, the exemplary shaped charge includes aliner 1241 disposed adjacent anexplosive load 1242. Theliner 1241 is configured for retaining theexplosive load 1242 within acavity 1243 defined at least in part by acylindrical sidewall 1244 including afirst sidewall portion 1245 and asecond sidewall portion 1246. Acap 1247 closes the shapedcharge cavity 1243 from a surrounding environment as previously discussed with respect to known encapsulated shaped charges. In an aspect, thecap 1247 may not need to be crimped onto thesidewall 1244, due, for example, to the protection that thecontrol module section 130 andtail section 180 provide against the shaped charges 1240 (i.e., caps 1247) impacting the wellbore casing. In another aspect, thecap 1247 may be formed from, without limitation, zinc, aluminum, steel, plastic, or other materials consistent with this disclosure. - In an aspect, the
explosive load 1242 includes at least one of pentaerythritol tetranitrate (PETN), cyclotrimethylenetrinitramine (RDX), octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazocine/cyclotetramethylene-tetranitramine (HMX), 2,6-Bis(picrylamino)-3,5-dinitropyridine/picrylaminodinitropyridin (PYX), hexanitrostibane (HNS), triaminotrinitrobenzol (TATB), and PTB (mixture of PYX and TATB). According to an aspect, theexplosive load 1242 includes diamino-3,5-dinitropyrazine-1-oxide (LLM-105). The explosive load may include a mixture of PYX and triaminotrinitrobenzol (TATB). The type of explosive material used may be based at least in part on the operational conditions in the wellbore and the temperature downhole to which the explosive may be exposed. - In the exemplary embodiment shown in
FIG. 14A , theliner 1241 has a conical configuration, however, it is contemplated that theliner 1241 may be of any known configuration consistent with this disclosure. Theliner 1241 may be made of a material selected based on the target to be penetrated and may include, for example and without limitation, a plurality of powdered metals or metal alloys that are compressed to form the desired liner shape. Exemplary powdered metals and/or metal alloys include copper, tungsten, lead, nickel, bronze, molybdenum, titanium and combinations thereof. In some embodiments, theliner 1241 is made of a formed solid metal sheet, rather than compressed powdered metal and/or metal alloys. In another embodiment, theliner 1241 is made of a non-metal material, such as glass, cement, high-density composite or plastic. Typical liner constituents and formation techniques are further described in commonly-owned U.S. Pat. No. 9,862,027, which is incorporated by reference herein in its entirety to the extent that it is consistent with this disclosure. When the shapedcharge 1240 is initiated, theexplosive load 1242 detonates and creates a detonation wave that causes theliner 1241 to collapse and be expelled from the shapedcharge 1240. The expelledliner 1241 produces a forward-moving perforating jet that moves at a high velocity. - With continuing reference to
FIGS. 12 and 14A-14B , anengagement member 1248 outwardly extends from anexternal surface 1249 of theside wall 1244 at a position substantially between thefirst sidewall portion 1245 and thesecond sidewall portion 1246. In an aspect, theengagement member 1248 may be configured for coupling the shapedcharge 1240 within a shapedcharge holder 1840 within anaperture 1213 at least partially within an interior 1214 of the perforatingassembly section body 1210. In the exemplary embodiment, theengagement member 1248 at least in part defines agroove 1250 circumferentially extending around theside wall 1244. Thegroove 1250 defines aseat 1251 for engaging a retention device, such as one ormore clips 1850 within the shapedcharge holder 1840 for retaining the shapedcharge 1240 within the shapedcharge holder 1840. When the shapedcharges 1240 are retained in the shapedcharge holders 1840, aninitiation point 1252 of each shapedcharge 1240 is adjacent theballistic channel 141 including, e.g., thereceiver booster 150 for initiating detonation of the shapedcharges 1240 in the exemplary embodiments. - With reference now to
FIG. 15 , a blown-up view of the shapedcharges 1240 received in the shapedcharge holders 1840 according toFIGS. 12-14B is shown. When a shapedcharge 1240 is received in a corresponding shapedcharge holder 1840,clips 1850 engage against theseat 1251 formed on thegroove 1250 defined by theengagement member 1248 extending outwardly from theexternal surface 1249 of theside wall 1244. As shown inFIG. 12 , areceiver booster 150 is positioned within theballistic channel 141 of theautonomous perforating gun 1200, adjacent to aninitiation point 1252 of each shaped charge. - In an aspect, shaped charges arranged according to any of the exemplary embodiment(s) shown in
FIGS. 10A-15 in which shaped charges are arranged adjacent to a detonator, receiver booster, donor charge, etc. in the absence or optional absence of a detonating cord, may be directly initiated by one or more of the adjacent detonator, receiver booster, donor charge, etc. - With reference now to the exemplary embodiment shown in
FIG. 16 , an autonomous perforatingdrone 1200 includes a perforatingassembly section 110 positioned between and connected to each of ahead portion 1285 at afirst end 101 of thedrone 1200 and acontrol module section 130 at a second end of thedrone 1200. Except where otherwise noted, various aspects of theexemplary drones FIG. 16 and for brevity will not be repeated here. Further, as previously noted, references to portions such as thehead portion 1285, perforatingassembly section 110, andcontrol module section 130 are to aid generally in describing the location of certain components and do not imply any particular assembly, delineation between sections, or other limits on the configuration of the structures and components. In an aspect, theexemplary drone 1200 shown inFIG. 16 may be an integrally formed piece, as additionally shown inFIGS. 17, 20 and 21 , and adrone body 1255 is referenced for simplicity to identify the structure(s) that define, house, or retain the various features of thedrone 1200, except where otherwise indicated. - The
control module section 130 in the exemplary embodiment shown inFIG. 16 andFIG. 20 is notably located upstream of the perforatingassembly section 110 with respect to an orientation of thedrone 1200 as it travels down a wellbore—that is, thecontrol module section 130 is above the perforatingassembly section 110 in thetail section 180 of thedrone 1200. With additional reference toFIG. 20 , thecontrol module section 130 includes a hollow interior portion 132 (as previously discussed) within which a control assembly, referred to interchangeably for purposes of this embodiment but without limitation and not implying a difference between the various embodiments, as a Control Interface Unit (CIU) 1804 is positioned and housed, as discussed below. As described below, theexemplary drone 1200 shown inFIGS. 16-21 includes a configuration in which, e.g., shaped charges carried by the drone are detonated in a top-down sequence, while still addressing problems in the existing art in an alternative approach from embodiments of a drone in which shaped charges are detonated in a bottom-up sequence, as disclosed herein. - As previously described, both the
head portion 1285 and thetail section 180 of thedrone 1200 may be formed withfins 181. Particularly pronouncedfins 1281 may be present on one or both of thehead portion 1285 and thetail section 180 and may be used, for example, to further lessen impacts against critical components of thedrone 1200 and/or provide an engagement means for a mechanical implement to grip and move the drone as part of a management and/or launcher system for drones, for example as described in co-owned U.S. patent application Ser. No. 16/423,230, incorporated herein by reference. -
Tail section 180/control module section 130 may further include pass-throughholes 1260 in a rear area of thetail section 180/control module section 130. The pass-throughholes 1260 may, without limitation, provide a channel for fluid running throughfins 181 to flow through, thus reducing friction on thedrone 1200, and may also be part of an engagement structure by which a mechanical implement for moving the drones, as mentioned above, may engage thedrone 1200 for moving it as part of moving, making an electrical connection to, and/or launching thedrone 1200, or other operations of the like. With additional reference toFIGS. 17 and 20-21 , thecontrol module section 130 may further include apassage 1265 through thedrone body 1255 for accessing a sealingaccess plate 1275 that encloses, seals, and protects the components within thehollow interior 132 of thecontrol module section 130. Thepassage 1265 is discussed further below. - As previously described with respect to other embodiments, the perforating
assembly section 110 includes at least oneaperture 1213 configured for receiving ashaped charge 140 at least in part within thebody 1255 of thedrone 1200. For purposes of the embodiment(s) shown inFIGS. 16-21 , retaining the shapedcharges 1240 within theapertures 1213 may be accomplished by any known means. In the exemplary embodiment ofFIG. 16 , retaining the shapedcharges 1240 within theapertures 1213 may be accomplished according to the shaped charges and associated assemblies shown and described with respect toFIGS. 12-15 . For purposes of convenience and not limitation, such description or labeling is not repeated here. - The exemplary embodiment(s) shown in
FIGS. 16, 17, 20, and 21 include opposingapertures 1213 and thus shapedcharges 1240, such that the charges will ideally fire at 180 degrees to each other. The ballistic interrupt 140, as previously described, is retained within thedrone body 1255 through anopening 462 in thedrone body 1255. The ballistic interrupt 140 in the exemplary embodiment and for purposes of preventing accidental or unintended detonation of the shaped charges is positioned, in any event, between an initiator within thecontrol module section 130 and a shaped charge initiator configured for being initiated by the initiator in the control module (as discussed with respect to other embodiment(s) and further described below). - The
head portion 1285 of thedrone 1200 is sized and shaped, as previously discussed, to help reduce impacts between thedrone 1200 and the wellbore casing as thedrone 1200 travels down the well. Theexemplary head portion 1285 shown inFIG. 16 is defined by a generally circularly-shapedouter body portion 1287 of thehead portion 1285. Aconcavity 1286 is formed substantially in the center of thehead portion 1285 and an upper ledge 1288 (FIG. 19 ) of theconcavity 1286 is defined by theouter body portion 1287. As described below with additional reference toFIGS. 19 and 20 , a series ofslopes 1291 extend inward into thehead portion 1285, between theouter body portion 1287 and abottom surface 1289 of theconcavity 1286, in a direction towards the perforatingassembly section 110. The series ofslopes 1291 taper inward towards a common center that is substantially aligned with abooster 150 within the drone body 1255 (as discussed with respect toFIGS. 20 and 21 ) and are interposed withslits 1290, resulting in the star-shaped profile of theconcavity 1286 seen in the straight-on view of the exemplary embodiment ofFIG. 19 . - As mentioned throughout this disclosure, the
head portion 1285, perforatingassembly section 110, andtail section 180 may take any form consistent with this disclosure. For example, an embodiment of a head portion may be torpedo or arrow shaped, have fins including a curved profile, or any other configuration consistent with the application(s). Theexemplary head portion 1285 shown inFIG. 16 may help with any or all, and without limitation, of increasing rotational speed of thedrone 1200 or slowing a forward speed of thedrone 1200 when it is traveling through a wellbore fluid, funneling the wellbore fluid through which it travels to help centralize the drone in the wellbore, and enhance the destructibility or break-up of thehead portion 1285 when thedrone 1200 is detonated. The shapedcharges 1240 of adrone 1200 as in the exemplary embodiment shown inFIG. 16 will detonate in a top-down sequence—i.e., upstream to downstream—when the drone is detonated, due to the configuration of the drone as described with respect toFIGS. 16-21 . - With reference to
FIG. 17 , the exemplary embodiment of thedrone 1200 shown inFIG. 16 is illustrated from a reverse perspective such that thesecond end 102 and rear of thecontrol module section 130 may be seen. Thecontrol module section 130 at thesecond end 102 includes the sealingaccess plate 1275 that seals the internal components of thecontrol module section 130. The sealingaccess plate 1275 includes the charging andprogramming contacts 1800 as discussed above. The charging andprogramming contacts 1800 are further described below especially with respect toFIGS. 18 and 20-25 . The sealingaccess plate 1275 is set back within arecess 1270 of thetail section 180, the recess defined by thebody portion 1255 of thedrone 1200 extending outwardly from thetail section 180. This may provide additional protection to the sealingaccess plate 1275 and allow for the inclusion of different structures that will now be described. - For example, the annular portion of the
tail section 180 extending beyond the sealingaccess plate 1275 defines awall 1271 around therecess 1270. The wall has aninterior surface 1272 on which engagement structures may be formed. In the exemplary embodiment shown inFIG. 17 , the engagement structures include receivingslots 1273 extending longitudinally through the wall as cut-outs between thesecond end 102 and towards the sealingaccess plate 1275. Theslots 1273 terminate at retainingchannels 1274 that are open to and extend from the slots in a circumferential direction around theinterior surface 1272 of thewall 1271. Theslot 1273/channel 1274 configuration may receive a complimentary connecting element through theslot 1273 and into thechannel 1274, and thereby be securely yet removable retained to thesecond end 102 of thedrone 1200. The connection may be, without limitation, to another autonomous perforating drone having a complementary connecting structure on its head portion, to a mechanical implement for engaging and holding thedrone 1200 such that thedrone 1200 may be moved and/or loaded into a wellbore, or may be an attachment means for other wellbore tools, such as data collection devices, to connect to thedrone 1200. In a case where a series of drones or wellbore tools are connected in series as a string, an aspect of the string may be that a single drone or tool, for example the most upstream drone or tool, contains a single CIU for controlling each drone or tool in the string. -
FIG. 18 shows a rear plan view of theexemplary drone 1200 shown inFIG. 17 . As previously discussed, the rear plan view shows the relationship between the different components, including thepassages 1260,slots 1273, and pronouncedfins 1281, of which one or more may be used to engage with a mechanical implement for moving thedrone 1200 as discussed above. Charging andprogramming contacts 1800 are accessible through the sealingaccess plate 1275. Sealingaccess plate 1275 additionally includes a plurality ofslits 1276 formed in the sealingaccess plate 1275 for providing the sealingaccess plate 1275 with additional manipulability such that the sealingaccess plate 1275 may be attached to and removed from thedrone 1200 as discussed below with respect toFIGS. 20 and 21 . -
FIG. 19 shows a front plan view of theexemplary drone 1200 as shown inFIG. 16 , whereinpassages 1260 are visible through spaces between thefins 181 of thehead portion 1285. As previously discussed,FIG. 19 illustrates the star-shaped configuration of theconcavity 1286 in thehead portion 1285. Also visible inFIG. 19 is anaperture 1292 that opens certain areas of thedrone body 1255 to a surrounding environment. Theaperture 1292 may provide benefits in forming thedrone body 1255 or in a flow profile as thedrone 1200 travels through a wellbore. As discussed herein, theCIU 1804 may be provided in, e.g., a sealedcontrol module housing 138, and theCIU 1804 and/or other components may be sealed against the environmental aspects by known techniques, or those disclosed herein, such as for providing sealed boosters, detonators, shaped charges, and the like. - With reference now to
FIG. 20 , a partial cutaway of theexemplary drone 1200 is shown. TheCIU 1804 is housed within acontrol module housing 138 positioned within the hollowinterior portion 132 of thecontrol module section 130. The cross section shown inFIG. 20 depicts that charging andprogramming contacts 1800 include pin contact leads 1802 electrically connected to theCIU 1804, for example, to a programmable electronic circuit which may be contained on a Printed Circuit Board (PCB) 1805 (FIG. 23 ). The pin contact leads 1802 may be exposed through, and sealed within,apertures 1801 through the sealingaccess plate 1275. As previously discussed, a number of known techniques exist for sealing theCIU 1804 and, e.g., the pin contact leads 1802, from external conditions. - As further shown in
FIG. 20 , and with further reference toFIG. 21 , sealingaccess plate 1275 includes sealingportions 1276 on a periphery of the sealingaccess plate 1275. The sealingportions 1276 in the exemplary embodiment are formed from a material and configured with a geometry to form a seal within thepassages 1265 through thedrone body 1255. This technique both seals the internal components of thecontrol module section 130 from external conditions and allows the sealingaccess plate 1275 to be removed and re-secured within thecontrol module section 130, although other techniques as known and consistent with this disclosure may be used. - With continuing reference to
FIG. 20 , theCIU 1804 may contain such electronic systems such as power supplies, programmable circuits, sensors, processors, and the like, as described throughout this disclosure. In an exemplary embodiment, theCIU 1804 further includescapacitor 1803 power supplies, adetonator 133, and thedonor charge 134. According to previous embodiments, thedetonator 133 is configured for initiating thedonor charge 134 upon receiving a signal to detonate thedrone 1200. As further shown and discussed, below, with respect toFIGS. 23-25 , thedetonator 133 in the exemplary configuration may be surrounded by the one ormore capacitors 1803 for powering theCIU 1804 and associated components. Thedetonator 133 may include a Non-Mass Explosive (NME) body and thedonor charge 134 may be integrated with the explosive load of thedetonator 133. In an aspect of integrating thedonor charge 134 with the explosive load of thedetonator 133, the amount of explosive may be adjusted to accommodate thedonor charge 134 and the size and spacing of components such as aballistic channel 141 along which the jet from the donor charge propagates, and the ballistic interrupt 140 and areceiver booster 150 positioned within the ballistic channel. - In an aspect, the
CIU 1804 may include thePCB 1805 and a fuse for initiating thedetonator 133 may be attached directly to thePCB 1805. In an aspect of those embodiments, thedetonator 133 may be connected to a non-charged firing panel—for example, a selective detonator may be attached to thePCB 1805 such that upon receiving a selective detonation signal the firing sequence, controls, and power may be supplied by components of the PCB or CIU via the PCB. This can enhance safety and potentially allow shipping the fully assembled drone in compliance with transportation regulations if the ballistic interrupt is in the closed position. Connections for the detonator/detonator components on the PCB board may be, without limitation, sealed contact pins or concentric rings with o-ring/groove seals to prevent the introduction of moisture, debris, and other undesirable materials. - In an aspect, the
CIU 1804 may be configured without acontrol module housing 138. For example, theCIU 1804 may be contained within the hollowinterior portion 132 of thecontrol module section 130 and sealed from external conditions by thedrone body 1255 itself. Alternatively, theCIU 1804 may be housed within an injection molded case and sealed within thebody 1255. The injection molded case may be potted on the inside to add additional stability. In addition, or alternatively, thecontrol module housing 138 or other volume in which theCIU 1804 is positioned may be filled with a fluid to serve as a buffer. An exemplary fluid is a non-conductive oil, such as mineral insulating oil, that will not compromise the CIU components including, e.g., the detonator. Thecontrol module housing 138 may also be a plastic carrier or housing to reduce weight versus a metal casing. In any configuration including acontrol module housing 138 the CIU components may be potted in place within thecontrol module housing 138, or alternatively potted in place within whatever space theCIU 1804 occupies. - With continuing reference to
FIGS. 20 and 21 , and the exemplary embodiment, thedetonator 133 anddonor charge 134 are contained within acontrol module housing 138 and thedonor charge 134 is substantially aligned with theballistic channel 141. Upon detonation of thedetonator 133, thedonor charge 134 is initiated and the jet from thedonor charge 134 will pierce aportion 139 of thecontrol module housing 138 that is positioned between thedonor charge 134 and theballistic channel 141, according to operation as described throughout this disclosure. The ballistic interrupt 140 andreceiver booster 150 are positioned in a spaced apart relationship within theballistic channel 141, and the ballistic interrupt 140 lies between thedonor charge 134 and thereceiver booster 150 such that, in the closed position, the ballistic interrupt 140 prevents the jet from thedonor charge 134 from reaching and initiating thereceiver booster 150, as has been described herein. The ballistic interrupt 140 in the exemplary embodiments shown in each ofFIGS. 20 and 21 is shown in the open position—i.e., the through-bore 142 of the ballistic interrupt 140 is parallel and coaxial with the longitudinal axis of theballistic channel 141. As has been discussed herein, the ballistic interrupt 140 is movable between a closed and an open state by, for example and without limitation, rotating the ballistic interrupt 140 between open and closed states via thekeyway 461. - The
ballistic channel 141 is open to and extends from the hollowinterior portion 132 of thecontrol module section 130 towards the perforatingassembly section 110. As shown inFIGS. 20 and 21 , thereceiver booster 150 extends, within theballistic channel 141, through a length of the perforatingassembly section 110 adjacent the shapedcharges 140 retained in the shapedcharge apertures 1213 extending into a portion of thedrone body 1255. The shapedcharges 1240 in the exemplary embodiments shown inFIGS. 20 and 21 are received and secured in the shapedcharge apertures 1213 in substantially the same was as has been described with respect toFIGS. 12-15 and will not be repeated here. Accordingly, aninitiation end 1252 of the shapedcharges 1240 within the shapedcharge apertures 1213 are, by the exemplary configuration, directly initiated by detonation of thereceiver booster 150. In alternative embodiments, the configuration may be applied with one or more of a detonator, detonating cord, or other initiation device consistent with thereceiver booster 150 in theballistic channel 141, in place of or in combination with thereceiver booster 150. -
FIGS. 22-25 illustrateexemplary CIU 1804 assemblies for use in the exemplary embodiments. For example,FIG. 22 shows thecontrol module 137 includingcontrol module housing 138 in which theCIU 1804 and related and/or other components may be housed within thecontrol module section 130. Thecontrol module housing 138 includesportion 139 positioned between thedonor charge 134 and theballistic channel 141 when thedrone 1200 is assembled.Control module 137 additionally includesopenings 1806 for pin contact leads 1802 from theCIU 1804 to pass into theapertures 1801 of the sealingaccess plate 1275 and remain exposed and available for an electrical or power connection to an outside control unit. In the event that the exemplary drone(s) is being moved or loaded into a wellbore using a mechanical implement for gripping, holding, engaging to the drone, the exemplary embodiment(s) shown inFIGS. 16-21 provide the benefit of the charging andprogramming contacts 1800 being positioned and exposed in the area of engaging structures on the drone where a mechanical tool is likely to engage the drone. Thus, the connection to charge a power source of the drone or program the drone may be accomplished when the drone is engaged for moving/loading. The charging andprogramming contacts 1800 may also be used as part of a function test, safety test, arming procedure, data retrieval, and the like. -
FIG. 23 shows theexemplary CIU 1804 for use with certain exemplary embodiments of the drone. As discussed previously, theCIU 1804 includes aPCB 1805 to which adetonator 133 is directly attached and in which thedonor charge 134 is integrated with theexplosive load 133 b (FIG. 23A ) of thedetonator 133.FIG. 23A shows the arrangement in which adetonator fuse 133 a, which may be directly attached to thePCB 1805, is connected to initiate thedetonator 133, namely theexplosive load 133 b of thedetonator 133. Thedonor charge 134 being integrated with thedetonator 133 configures thedonor charge 134 to use theexplosive load 133 b of the detonator directly, instead of to initiate a separate, or full, explosive load of thedonor charge 134.Capacitors 1803 surround the detonator. Pin contact leads 1802 extend from, and are electrically connected to, e.g., a programmable electronic circuit on thePCB 1805 and/or thecapacitors 1803, for charging thecapacitors 1803. -
FIG. 24 shows a cross section of thecontrol module 137 with theexemplary CIU 1804 contained within aninner area 320 of thecontrol module 137 defined by thecontrol module housing 138. From this vantage, taken along line ‘F’ ofFIG. 23 , thecapacitors 1803 are seen surrounding at least a portion of each of thedetonator 133 and thedonor charge 134, while thePCB 1805 and pin contact leads 1802 extend in a direction out of the page. -
FIG. 25 is another vantage of theexemplary CIU 1804, taken along the line ‘S’ ofFIG. 23 . Here, again,capacitors 1803 surround at least a portion of thedetonator 133 and thedonor charge 134. Fuse 133 a may be connected directly to thePCB 1805 and electrically connected to a programmable electronic circuit for receiving a selective detonation command for thedetonator 133 and initiating detonation in response. Pin contact leads 1802 are connected to and extend from thePCT 1805 for connection/use as part of the charging andprogramming contacts 1800. - With respect to the exemplary embodiment(s) presented in
FIGS. 16-26 , uses, methods, and variations as have been discussed throughout this disclosure remain applicable and are not repeated here. - The exemplary embodiments presented herein may be used for deploying a variety of wellbore tools downhole, as previously discussed. Thus, neither the description nor the claims necessarily excludes the use of the autonomous perforating drone described throughout this disclosure of deploying a variety of wellbore tools for activation.
- The present disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems and/or apparatus substantially developed as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. Those of skill in the art will understand how to make and use the present disclosure after understanding the present disclosure. The present disclosure, in various embodiments, configurations and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and/or reducing cost of implementation.
- The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
- In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms “a” (or “an”) and “the” refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. Furthermore, references to “one embodiment”, “some embodiments”, “an embodiment” and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as “first,” “second,” “upper,” “lower” etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.
- As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”
- As used in the claims, the word “comprises” and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, “consisting essentially of” and “consisting of.” Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that variations in these ranges will suggest themselves to a practitioner having ordinary skill in the art and, where not already dedicated to the public, the appended claims should cover those variations.
- The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
- The foregoing discussion of the present disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the present disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the present disclosure are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the present disclosure may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the present disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, the claimed features lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the present disclosure.
- Advances in science and technology may make equivalents and substitutions possible that are not now contemplated by reason of the imprecision of language; these variations should be covered by the appended claims. This written description uses examples to disclose the method, machine and computer-readable medium, including the best mode, and also to enable any person of ordinary skill in the art to practice these, including making and using any devices or systems and performing any incorporated methods. The patentable scope thereof is defined by the claims, and may include other examples that occur to those of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims (20)
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US16/272,326 US10458213B1 (en) | 2018-07-17 | 2019-02-11 | Positioning device for shaped charges in a perforating gun module |
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US16/537,720 US11408279B2 (en) | 2018-08-21 | 2019-08-12 | System and method for navigating a wellbore and determining location in a wellbore |
US16/542,890 US20200018139A1 (en) | 2018-05-31 | 2019-08-16 | Autonomous perforating drone |
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