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Guardian II/EBW System TABLE OF CONTENTS

INTRODUCTION ............................................................................................................... 3
Exploding Bridgewire (EBW) Detonator .................................................................. 3
Firing Process ........................................................................................................ 3
EBW Detonator Selection Table ............................................................................. 5
HTC Trade Compliance review and approval ......................................................... 5

Guardian Modules ........................................................................................................... 6

Guardian II (PX-1) .................................................................................................. 6
Specifications ............................................................................................. 6
Safety Features .......................................................................................... 7
Certification ................................................................................................ 7
Operation ................................................................................................... 7
Negative (normal) firing ................................................................... 7
Positive (reverse) firing ................................................................... 7

Wellsite Operations ......................................................................................................... 8

Solvent Compatibility............................................................................................... 8
Safety .................................................................................................................... 8
Grounding checks ....................................................................................... 9
Before Connecting ground clamps .................................................. 9
After Connecting ground clamps ..................................................... 9
General ................................................................................................................ 10
Wellsite Preparation ............................................................................................. 10
Cable Conductor Resistance ..................................................................... 10
CCL .......................................................................................................... 10
Line Current Determination ....................................................................... 10
EBW Detonator Checkout ......................................................................... 10
Guardian II Generic Arming Procedure ................................................................ 11
Firing .................................................................................................................... 12

Vendor Document
Ecosse inc PX-1 Operating Instructions and Frequently Asked Questions

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Guardian II/EBW System TABLE OF CONTENTS

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Guardian II/EBW System INTRODUCTION

INTRODUCTION

The Guardian II system is a ballistic fire control system specifically designed for field operations
where, for safety and economic considerations radio silence or shut down of cathodic protection or
welding processes would be impractical. The Guardian II system provides immunity from these
hazards, as well as stray voltages and lightning-induced electrical signals.

The Guardian II system consists of two main components: (1) Exploding Bridgewire, or EBW
detonators and, (2) electronic modules known as Guardian II modules that are required to fire them.
In this section we look at the how these components function and how they are installed into the
ballistic systems that support their use.

EXPLODING BRIDGEWIRE (EBW) DETONATOR

An EBW detonator does not contain a primary explosive and is immune to high order initiation by
external power sources. To fire an EBW detonator requires the use of a special electronic package,
known as a Guardian module.

As with a conventional detonator, the EBW utilizes a bridgewire to initiate a chain reaction, however,
the main difference between the two devices is the way in which power is applied to this bridgewire.

A typical EBW detonator is illustrated in Figure 1.

Figure 1

FIRING PROCESS

With a conventional detonator the bridgewire is heated to a point where it causes ignition of a primary
explosive. In an EBW detonator power from an electronic module (Guardian II) is applied so rapidly
that the bridgewire literally explodes.

Activating the Guardian II module causes a capacitor to charge and release its stored electrical
energy into the bridgewire of the EBW detonator. This occurs so rapidly that the inertia of the
bridgewire holds it together until it has absorbed a significant amount of energy. When the inertia of
the bridgewire is finally overcome the wire explodes, imparting enough kinetic and thermal energy to
initiate a secondary explosive in the detonator. If the current is too low or the current rise-time is too
slow, insufficient energy is delivered to the bridgewire and it breaks like a fuse wire without initiating
the explosive.

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Guardian II/EBW System INTRODUCTION

1. There are two suppliers for the EBW detonators currently in use by the field:

• Reynolds Industries (RISI) - RP series detonators

• Pacific Scientific (PS) - PS series detonators

The RP and PS detonators have a very similar design using a gold bridgewire with a resistance of
about 0.05-0.07Ω.

RISI detonators use RDX explosive and are limited to a maximum temperature of 325oF for one
hour.

PS detonators use CP and HNS explosive and are rated for use at a maximum temperature of
400o F for sixteen hours.

Exceeding the "time at temperature" for these devices increases the probability of low order
detonation or misfire.

2. EBW detonators are immune to initiation by RF signals that are generally associated with the
oilfield environment. Typical stray voltages (e.g. 115-240VAC @ 50-60Hz, or 70-90 VDC from a
welding machine) will not cause these devices to detonate, but they can cause the bridgewire to
fail and may cause the detonator housing to blow apart. Although this will not initiate the
explosive in the detonator, the disintegration of the shell may be violent enough to be hazardous
to personnel. All the precautions used when handling and storing conventional detonators apply
to EBW detonators. Refer to Explosive Safety and Explosive Storage sections for further
information.

3. For setting-tool and chemical-cutter applications, an igniter is used rather than a detonator.
Igniters contain less explosive material than a detonator and give a less violent ignition. Igniters
are manufactured by RISI. The bridgewire in these devices is similar to that used in the
detonators; but instead of explosive, a thermite mix is used to generate a flame output. They are
rated for use at a maximum temperature of 400o F for sixteen hours, after which the probability of
low order detonation or misfire increases. Table 1 shows the standard EBW detonators and
igniter used in the field.

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Guardian II/EBW System WELLSITE OPERATIONS

EBW DETONATOR SELECTION TABLE

Table 1 - EBW device reference table

EBW Detonator PN DESCRIPTION ECCN

RP-880 EBW F163841000 EBW Detonator for Fluid disabled applications 3A232

EBW Detonator for Fluid disabled applications

PS-420 EBW F261907000 3A232
Requires booster P/N F310285000

CLCP EBW 2-300180-4 A2002379000 EBW Detonator for Fluid disabled applications 3A232

RP-800 EBW F180375000 EBW Detonator 3A232

EBW Detonator (To be phased out and replaced

RP-810 EBW F264504000 3A232
by RP-800 EBW)

CLCP EBW 2-300180-3 A2002378000 EBW Detonator for Fluid disabled applications 3A232

SQ-80 IGNITOR 188-7382 F162635000 EBW Igniter 3A232

EBW Module PN DESCRIPTION ECCN

PX-1 Module F267539000 Module: PX-1 EXPNDBL FIRESET ASSY EAR99

The specifications and applications for EBW detonators/igniters can be found in the Detonators
section of the CHOM.

Shipping documents, i.e., invoice, air waybill (AWB) or bill of lading (B/L) for all exports and
re-exports of licensed materials must be sent by the consignor to:
[email protected] for HTC Trade Compliance review and approval prior to
shipping. Export license info must be shown on the invoice, AES, AWB or B/L with proper ECCN.

Final complete documents must be sent to the same email address listed above by the consignor
after the shipment is completed.

Licensed materials should not be combined into kits.

Note that the requirement for HTC Trade Compliance review and approval applies to the EBW
detonators listed above in Table 1 (ref. OTB 2007-44A).

A REYNOLDS P/N 188-2465 Dummy EBW (BA P/N F262329000) is also available for training and
demonstration purposes only. This item's use is very stressful on the PX-1 electronics. It contains
no explosive, and is not subject to the above shipping restrictions.

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GUARDIAN II MODULE

The Guardian II module is the electronic device that supplies the energy required to initiate the EBW
detonator. It is recommended to use the Guardian II (PX-1) module for safe perforating operations.

WARNING:
EXTREME CARE MUST BE EXERCISED WHEN WORKING WITH GUARDIAN II MODULES.
VERY HIGH VOLTAGE AND CURRENT ARE DISCHARGED WHEN FIRED. THESE VOLTAGES CAN BE
LETHAL!
HIGH VOLTAGE MAY REMAIN FOR MORE THAN ONE MINUTE AFTER POWERING DOWN.

Guardian II (PX-1)
The Guardian II (PX-1) module is an
expendable device that generates the
high current needed to initiate EBW
detonators and igniters. The module is
intended for one-time use and requires
no maintenance. It is compatible with
the F2 and Selectfire systems and with
standard PFC tools.

Specifications
Part number F267539000

Dimensions: 0.82" W x 0.74" H x 5" L

Weight: 75gm

Temperature Rating1: -13o F to +437oF ( -25oC to +225oC) / 2 hours

Input: 200-230VDC @ 160-260mA

Output (Firing) Voltage: 5000V+15% / >2000A / <250ns

Will fire EBWs thru 10ft of twisted-pair wire.

Rated Lifespan: 1 x 1 full discharge into detonator

Wiring color code: Red = Positive input

Black/White = Negative input (either can be ground)
Spring terminals = Output to detonator

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Guardian II/EBW System WELLSITE OPERATIONS

Safety Features2
Negative DC: - 600 VDC
Positive DC: +150 VDC
AC: 40 Hz-20 kHz 600 VAC
32kHz-2MHz 100 VAC
RF interference: 260kHz-500MHz 50V/m
500MHz-1GHz 100V/m
1GHz-18GHz 300V/m
Electrostatic discharge: 25kV 500pF 5kohm
30kV 400pF - 250ohm
Lightning strike: nearby 20kA - 100m
direct strike 70kA / 280A

Notes:

1. The temperature rating for the system being used will be determined by the component with the
lowest temperature rating.

2. All safety features were tested and certified at Sandia National Laboratories by Orion
International Technologies Inc. All tests were done at ambient temperature, and all tests (apart
from lightning strikes) were repeated at 93oC – 121oC.

Certification
The Guardian II system (PX-1 Expendable Fireset) has been certified at Sandia National
Laboratories by Orion International Technologies Inc.

Operation

The Guardian II (PX-1) module is activated by applying DC voltage to the red (+ve) and
black/white (- ve) input wires.

Negative (normal) firing

Connect the black/white wire to the gun through wire and the red wire to ground.

Positive (reverse) firing

Connect the red wire to the gun through wire and the black/white wire to ground.

Red must always be positive with respect to the black/white wire, regardless of the polarity
to be used for firing. Either input wire can be tied to ground.

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Guardian II/EBW System WELLSITE OPERATIONS

WARNING:
EXTREME CARE MUST BE EXERCISED WHEN WORKING WITH GUARDIAN II MODULES. VERY
HIGH VOLTAGE AND CURRENT ARE DISCHARGED WHEN FIRED. THESE VOLTAGES CAN BE
LETHAL!

HIGH VOLTAGE MAY REMAIN FOR MORE THAN ONE MINUTE AFTER POWERING DOWN.

CAUTION:
THE GUARDIAN FIRESET IS INTENDED FOR ONE-TIME USE TO INITIATE EBW OR EFI
DETONATORS. ALL FIRESETS ARE TEST-FIRED BY ECOSSE BEFORE BEING SHIPPED, AND TO
AVOID PREMATURE FAILURES FURTHER TESTING IN THE FIELD PRIOR TO USE IS NOT
PERMITTED. ANY GUARDIAN THAT IS TEST-FIRED FOR DEMONSTRATION OR
TROUBLESHOOTING PURPOSES SHOULD BE EXPECTED TO FAIL VERY QUICKLY, AND UNDER
NO CIRCUMSTANCES SHOULD IT BE USED ON A JOB AFTERWARD.

Wellsite Operations

Solvent compatibility
Solvents and degreasers containing the ingredient d-Limonene have been used in many cleaning
agents for a number of years because of its effectiveness and its environmentally-friendly nature.
d-Limonene belongs to a group of compounds called terpenes. It is an extract from the peels of
citrus fruits, which usually gives products containing it a pleasant citrus smell. Unfortunately,
d-Limonene also readily penetrates and loosens conformal silicone coatings, such as that used on
the bottom of the PX-1 circuit board to protect the board from moisture. If moisture and d-Limonene
are both present with the PX-1 in a confined space at elevated temperatures, arcing can occur in the
high voltage area of the PX-1 circuit board, causing a misrun. It is recommended that cleaning
agents containing terpenes not be used on any subs or housings that will contain the PX-1. One
example of this type of cleaner which is in common use is Current Issue, part number F263143000.
If such a cleaning agent is used, care should be taken to remove all traces of it and any residual
moisture from the hardware before installing the PX-1.

Safety
The Guardian II system is immune to:

• AC voltages
• RF signals
• Voltage surges (including the effects of nearby lightning strikes)
• Positive polarity DC voltages below 150V
• Negative polarity DC voltages sources

Explosive operations can be conducted without the need to shut down radio transmitters, electric
welding equipment, or cathodic protection circuits. Restrictions regarding maximum acceptable stray
voltage levels measured from wellhead to ground are detailed on the EXPLOSIVE SAFETY
CHECKLIST - reference EXPLOSIVES SAFETY section of the CHOM. Grounding clamps must be
used to adequately ground the winch unit (and data acquisition unit if separate) to the rig structure
and to the wellhead.

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Guardian II/EBW System WELLSITE OPERATIONS

GROUNDING CHECKS

Before Connecting ground clamps

1. Wellhead to rig voltage (AC and DC), less than 5V

After Connecting ground clamps

2. Wellhead to rig voltage (AC and DC), less than 5V
3. Wellhead to clamp and rig to clamp voltage (AC and DC), less than 5V
4. Wellhead potential monitor (WPM) installed and reads less then 5 V

All other safety procedures still apply and must be followed. This includes establishing a restricted
area for arming guns and the posting of explosive warning signs. Refer to the EXPLOSIVES
SAFETY section of the CHOM for full safety requirements.

Although welding operations do not need to be stopped during perforating operations utilizing the
Guardian II system and EBW detonators, welding is still prohibited within 50 ft. (15m) of any area
designated as a safe loading area and in the restricted area for arming guns. The definition of a safe
loading area is described in the EXPLOSIVES SAFETY section of the CHOM.

Although the Guardian II system is immune to the effect of near lightning strikes, lightning poses
safety risks not related to the detonator. Therefore, restrictions for operations during electrical storms
must be followed.

WARNING:

ALL NON-EBW OPERATIONS INVOLVING THE USE OF EXPLOSIVES MUST OBSERVE STANDARD OPERATING
PROCEDURES FOR RADIO SILENCE, WELDING ACTIVITIES AND STRAY VOLTAGES.

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Guardian II/EBW System WELLSITE OPERATIONS

General

1. Surface System Requirements

For reliable operation, the tool should be powered up by a stable DC power source with minimal
ripple and noise.
• 3957XC perforating panels or later revision can be used without modification.
• 3957 panels of earlier revision levels must be updated by implementing FMN #95-21.
• 2010 and 5756 panels as used in the ECLIPS-S system have been tested successfully with the
Guardian II system and require no modifications.

The modification number for the 1857XA perforating panel (red face plate) is FMN 96-12.

2. Do not use Scotchlok connectors for operations above 300oF.

Because of the high voltages involved, INPUT = 200-230 VDC and OUTPUT = 5000 VDC, all
splices must be well insulated. If wires are spliced together by twisting the bared ends together,
use self-amalgamating rubber tape to insulate the connections.
Use 213314-000 Plymozone self-fusing rubber tape for connections not exposed to wellbore.
Use 255459-000 Grey silicone self-fusing tape for connections exposed to wellbore. This tape is
more resistant to being dissolved by pressure control grease and well fluids.

3. Very high, fast-rising, current pulse is required to fire EBW detonators; the length and
configuration of the output wires between the firing tool and the detonator can have a significant
effect on the tool's efficiency. For maximum reliability the detonator wires should be kept as short
as possible and they should be twisted together along their length. Although testing has shown
that wires of 16 inches are acceptable, a maximum length of 8-12 inches is preferred.

Wellsite Preparation

Cable Conductor Resistance

• Use a jumper to short the contact button in the cablehead to the cablehead body, then
measure and record the line resistance at the Line Control Panel using a digital multimeter.

CCL
• If running a shooting CCL, perform the standard checks. Refer to the section on Casing
Collar Locators in the CHOM, and/or the Downhole Tools Maintenance Manuals.

Line Current Determination

• Before commencing any gun preparation, connect the auxiliary hardware (CCL, PFC etc.) to
be run onto the cablehead, then monitor and record the DC current indicated on the surface
Power Supply required to provide 230VDC to the bottom of the tool string. Do not leave
power applied any longer than absolutely necessary to obtain the line current measurement.
• Remove all power to the wireline and follow the safety procedures for explosive operations.

EBW Detonator Checkout

The leg-to-leg resistance of an EBW detonator is about 50milliΩ. Company approved digital
multimeters cannot accurately read resistances in this range; a reading less than 1Ω is
considered acceptable. Leg-to-shell readings should be infinite. Twist the detonator lead wires
along their length to reduce inductance.
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Guardian II/EBW System WELLSITE OPERATIONS

Guardian II Generic Arming Procedure

NOTE:

AT THE WELLSITE OBSERVE ALL NORMAL SAFETY PROCEDURES.

FOR EXCEPTIONS SEE Wellsite Operations - Safety.

WARNING:

ELECTRIC-BEFORE-BALLISTIC-ARMING (EBBA) PROCEDURE MUST BE FOLLOWED.

Guardian II (PX-1) Arming Procedure

1. Verify that any power supplies attached to the wireline are disabled.

2. Connect cablehead, CCL and other components to the wireline.

3. Connect the Guardian II (PX-1)

Red wire = +ve
Black/white wire = -ve

4. Place the detonator in an explosive shield pointed away from people in the area, in order to
diminish any possible bodily harm.

5. For Selectfire or F2 operations refer to the Selectfire chapter in the CHOM.

6. Verify that the voltage at the output sockets is <10mV by checking with an approved multimeter,
then connect the EBW detonator or igniter to the Guardian II Fireset. If the meter reads >10mV
the cause must be found and resolved before connecting the detonator or igniter. The detonator
wires should be as short as possible (ideally < 8"). Remove approx 1/3" of insulation from the
detonator wires using approved wire strippers; depress the orange levers on the output sockets
and insert detonator leg wires fully into the spring terminals. (Note: the levers operate more
smoothly when pushed on the right side, as viewed toward the sockets.) Release the levers and
check to confirm good contact and retention.

WARNING:

Both wires from the EBW detonator or igniter must be connected directly to the
output sockets of the PX-1 Fireset. It is not permitted to connect only one wire
from the EBW to an output socket of the Fireset and the other wire to ground.

Failure to connect the detonator correctly as described above will disable some
of the safety circuitry in the Guardian module and will invalidate its safety
certification. This is not permitted under any circumstances.

7. The tool is now ready for ballistic arming.

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Guardian II/EBW System WELLSITE OPERATIONS

Firing1

The PX-1 Fireset does not draw any current until its switch-on voltage is reached. The switch-on
voltage varies with temperature, from ~208VDC at ambient temperature to a maximum of ~230VDC
@ ~390ºF (200ºC). As soon as the PX-1 switches on, it draws between 150 - 250mA, which results
in an immediate drop in Cablehead Voltage due to the resultant increased IR drop in the wireline.
The engineer must compensate for this dynamic change in the load current while increasing the
surface voltage by continuing to increase the voltage to a pre-determined level required to obtain a
target firing voltage at the cablehead.

Determining the estimated maximum surface voltage to fire the PX-1 requires some assumptions
and calculations to be made. In order to make a conservative estimate and minimize the risk of a
misrun, assume the maximum switch-on voltage for the PX-1 at 230VDC, and an increase in load
current of 200mA (the median value of the range stated above) when the PX-1 switches on. The
estimated maximum surface voltage will be 230VDC plus the IR drop between the surface power
supply and the cablehead.

The line current @ 230VDC not including the current required by the PX-1 was recorded during the
Wellsite Preparation (ref. Line Current Determination); add 200mA to this value for the estimated
total load current. The Cable Conductor Resistance was also measured and recorded during the
Wellsite Preparation. The total line resistance in the firing circuit includes the current return path
through the cable armor. The casing/tubing and the wellbore fluid will also affect the resistance of
the current return, but since these factors can't be accurately determined, the conservative approach
is to assume these to be non-conductive and simply calculate the resistance of the cable armor from
the drum to the perforating gun.

The armor resistance in Ω/1000' is obtained from the cable spec. sheet and multiplied by the gun
depth/1000' to calculate the armor resistance. This value is added to the conductor resistance and
the sum is multiplied by the estimated total load current to determine the IR drop, or voltage drop of
the wireline that must be added to the 230VDC switch-on voltage for the PX-1.

Consider the following example:

Measured Cable Conductor Resistance: 70Ω

Measured Line Current (from Wellsite Preparation): 215mA
Rochester 3/8" Mono Conductor Cable 1-H-375A Armor resistance = 1.6Ω /1000'
Perforating depth: 12,000'

Total line resistance: 70 + (1.6 x 12) = 89.2Ω

Estimated total load current: 215 + 200 = 415mA

Wireline voltage drop: IR = .415 x 89.2 = 37VDC

Estimated maximum surface voltage to fire PX-1: 230 + 37 = 267VDC

1
Refer to the Ecosse inc publication "PX-1 Newsletter – Baker Atlas edition – February 2008" in TPB# 2008-03.
Note that there is also an Excel file referenced in the publication that is available on the OTM, which provides an alternate
method to perform the above calculations automatically. Click on "PX-1 firing voltage.xls" to open this file.
It's recommended that you close MS Excel after reviewing or using the file for calculations.

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Guardian II/EBW System WELLSITE OPERATIONS

Firing (cont'd)

1. To fire, smoothly increase the voltage over 5 seconds from zero to the previously-determined
required surface voltage (ref. previous page), hold at that voltage for 2 - 3 seconds, then ramp
down quickly to zero. The current will increase slowly as the voltage is ramped up then jump up
about half-way through the firing sequence as the Guardian switches on. The PX-1 doesn’t draw
any significant power or start to heat up until it switches on at 200V or more, so if it’s awkward to
do the ramp-up in one continuous motion, pause below that voltage level to reposition your hand
on the variac.

2. When the Guardian fires the gun, the attached wiring will be destroyed. The current should kick
and will usually increase substantially as the wiring shorts out.

3. The variac must be ramped down before releasing the trigger after firing the gun; if the voltage is
switched off, the extremely high voltage induced by the CCL coil is likely to cause insulation
failure.

4. If a misfired gun is returned to surface, disarm it in the following sequence:

a. Check for trapped pressure; pressure can be trapped whether or not the gun has fired.
b. Disconnect detonator from the detonating cord (ballistic disarming).
c. Disconnect detonator from the Guardian II (electric disarming).
d. Disconnect firing tool from the gun wiring.

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