U.S. patent application number 12/887870 was filed with the patent office on 2011-08-18 for debris removal system and method for pressure controlled wellbore drilling and intervention operations.
Invention is credited to Karl Demong.
Application Number | 20110198080 12/887870 |
Document ID | / |
Family ID | 44368829 |
Filed Date | 2011-08-18 |
United States Patent
Application |
20110198080 |
Kind Code |
A1 |
Demong; Karl |
August 18, 2011 |
DEBRIS REMOVAL SYSTEM AND METHOD FOR PRESSURE CONTROLLED WELLBORE
DRILLING AND INTERVENTION OPERATIONS
Abstract
A wellbore debris screening system used with controlled annulus
pressure wellbore intervention and drilling operations includes a
wellbore annulus seal configured to pressure isolate an annular
space between a conduit inserted into the wellbore and the wellbore
wall. A first screening device is coupled to an output of the
annulus seal. second screening device is coupled to the output of
the annulus seal. Valves are provided that are operable to
selectively divert flow out of the annulus to the first and to the
second screening sections.
Inventors: |
Demong; Karl; (Calgary,
CA) |
Family ID: |
44368829 |
Appl. No.: |
12/887870 |
Filed: |
September 22, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61305708 |
Feb 18, 2010 |
|
|
|
Current U.S.
Class: |
166/267 ;
166/227 |
Current CPC
Class: |
E21B 21/106 20130101;
E21B 21/08 20130101; E21B 21/063 20130101 |
Class at
Publication: |
166/267 ;
166/227 |
International
Class: |
E21B 43/02 20060101
E21B043/02; E21B 43/08 20060101 E21B043/08 |
Claims
1. A wellbore debris screening system used with controlled annulus
pressure wellbore intervention and drilling operations, comprising:
a wellbore annulus seal configured to pressure isolate an annular
space between a conduit inserted into the wellbore and the wellbore
wall; a first screening section coupled to an output of the annulus
seal; a second screening device coupled to the output of the
annulus seal; and valves operable to selectively divert flow out of
the annulus to the first and to the second screening sections.
2. The system of claim 1 further comprising pressure sensors in
hydraulic communication with an intake side and an outlet side of
each of the first and second screening sections.
3. The system of claim 1 further comprising a bypass line coupled
between the output of the annulus seal and an outlet manifold
coupled to outlet side of the first and second screening
sections.
4. The system of claim 1 further comprising a controllable orifice
choke disposed between the outlet manifold and a pressure tank, the
choke operable to maintain a selected pressure in the wellbore
annulus.
5. The system of claim 1 wherein each screening section includes
valves at its inlet and outlet to enable removal from the system
while maintaining fluid pressure within the screening section.
6. The system of claim 1 further comprising sensors associated with
each screening section, the sensors selected and arranged to enable
at least one of characterization of debris particle size, debris
particle shape, presence of water, oil, gas and fractional amounts
thereof.
7. The system of claim 3 further comprising a pressure actuated
burst disk disposed in either of the screening sections or the
bypass line.
8. The system of claim 1 wherein screens in each screening section
comprise at least two mesh sizes.
9. A method for collecting debris from a wellbore during wellbore
intervention operations, comprising: circulating fluid through the
interior of a pipe disposed in the wellbore to conduct the
intervention operations; returning the fluid up an annular space
between a wall of the wellbore and an exterior of the pipe;
maintaining a fluid seal at the surface between the annular space
and the pipe; discharging the fluid from below the fluid seal to at
least two parallel-connected, pressure sealed screening devices,
the discharging performed so that the fluid flows only through a
first one of the at least two screening devices; and when the first
one of the screening devices is determined to be full, diverting
flow to a second one of the at least two screening devices.
10. The method of claim 9 wherein determining when the first one of
the screening devices is full comprises measuring a pressure drop
between and inlet and outlet of the first one of the screening
devices.
11. The method of claim 9 further comprising hydraulically
isolating the first one of the screening devices and removing it
from any hydraulic circuit including the at least two screening
devices.
12. The method of claim 9 further comprising bypassing flow of
fluid around the at least two screening devices if at least one of
the screening devices become clogged and debris samples are not
needed at selected times.
13. The method of claim 9 further comprising sensing selected
parameters of the fluid moving through the at least to screening
devices to determine at least one of debris particle size, debris
particle shape, and fluid composition.
14. The method of claim 9 further comprising automatically dumping
one of the at least two screening sections at selected times and
recording a depth of the pipe in the wellbore at the selected
times.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Priority is claimed from U.S. Provisional Application No.
61/305,708 filed on Feb. 18, 2010.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to the field of wellbore
drilling wherein a drilling fluid circulation system is closed.
More specifically, the invention relates to devices for removing
cuttings and debris from a well annulus when the annulus is
pressure controlled and allowing cuttings size and shape
inspections, either remotely or by automatically or manually
removing samples from the system.
[0005] 2. Background Art
[0006] Certain types of wellbore drilling and intervention
operations are performed such that a pipe string, coiled tubing or
drill string is inserted into the wellbore and wherein an annular
space between the pipe string, coiled tubing or drill string is
closed by an annular pressure control device such as a dynamic
hydraulic seal, a rotating control head, rotating blowout preventer
and the like.
[0007] During the drilling or intervention operations, fluid may be
pumped through the pipe string, drill string or coiled tubing,
enter the wellbore at the lower end of the string or tubing, and
move up the annular space. In any drilling operation the normal
parameters monitored to determine performance include the rate of
penetration and rate and constituents of material returning up the
annulus. This is true of both a hand drill and a deep drilling rig.
In the case of drilling with an annular pressure control device
such as those described above, however, the return fluid and any
solids therein are circulated to a pressurized separation tank. It
is often only very intermittently that the tank is opened and
inspected for accumulation of debris.
[0008] There exists a need for a system to enable more frequent
characterization of debris returning from a well being operated
using an annular pressure control device.
SUMMARY OF THE INVENTION
[0009] A wellbore debris screening system according to one aspect
of the invention used with controlled annulus pressure wellbore
intervention and drilling operations includes a wellbore annulus
seal configured to pressure isolate an annular space between a
conduit inserted into the wellbore and the wellbore wall. A first
screening device is coupled to an output of the annulus seal. A
second screening device is coupled to the output of the annulus
seal. Valves are provided that are operable to selectively divert
flow out of the annulus to the first and to the second screening
sections.
[0010] A method for collecting debris from a wellbore during
wellbore intervention operations according to another aspect of the
invention includes circulating fluid through the interior of a pipe
disposed in the wellbore to conduct the intervention operations.
The fluid is returned up an annular space between a wall of the
wellbore and an exterior of the pipe. A fluid seal is maintained at
the surface between the annular space and the pipe. The fluid is
discharged from below the fluid seal to at least two
parallel-connected, pressure sealed screening devices, the
discharging performed so that the fluid flows only through a first
one of the at least two screening devices. When the first one of
the screening devices is determined to be full, flow is diverted to
a second one of the at least two screening devices.
[0011] Other aspects and advantages of the invention will be
apparent from the following description and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic drawing of a system according to the
invention.
DETAILED DESCRIPTION
[0013] 1. General Principles of a Debris Catcher According to the
Invention
[0014] This invention combines one or more pressurized debris
catchers that are connected upstream of a return separator pressure
tank. The debris catcher can have one or more screen sections that
are selectably inserted into the flow path to catch debris. The
screen sections can be individually hydraulically isolated while
the flow of drill debris and fluid from the well continues. The
concept is that periodically the screens are hydraulically isolated
and emptied, and the debris is weighed and characterized for size
and shape. The rate at which the debris fills the catcher can also
be recorded. In addition, pressure differential monitors and other
sensors can measure the pressure drop across each screen section,
providing data on the size of the cuttings generated or the
particles unloaded from the well. This sensing can be remote and
coupled with an automatic dump/flush of the screen, eliminating
need to manually disassemble the apparatus for cleaning and debris
removal.
[0015] The debris catcher facilitates the optimization of drilling
parameters such as weight on bit, flow rate, mud motor differential
pressure, and fluid return rate (in the case of a circulating or
flowing well condition). Changes in drilling parameters can be
correlated to changes in the return debris. Feedback can be used to
optimize the drilling process.
[0016] The pressurized debris catcher can also include pressure
sensors or gauges upstream and downstream of each screen section so
that fill up or plugging of the screen section can be identified if
pressure drop across the screen increases.
[0017] 2. An Example Debris Catcher Structure.
[0018] Referring to FIG. 1, an example of a debris catcher
according to the invention will be explained. A wellbore 10 may be
subject to operations such as drilling, workover, recompletion of
other intervention. In the present example, the well drilling or
intervention may be performed by a coiled tubing unit 12. As
explained in the Background section herein, the operations in the
wellbore 10 may also be performed, without limitation, by a
workover pipe string, a drill string or any other tubular device
that can be extended into the wellbore 10 for the purpose of
operating in the wellbore 10, and has the capability of having
fluid pumped through an internal passage 11 therethrough. An
annular space 13 between the coiled tubing 12 or other pipe may be
sealed at or near the surface by a rotating diverter, rotating
control head, rotating blowout preventer or similar device 14 that
seals the upper end of the wellbore annulus 13 while enabling
movement of the intervention pipe (e.g., coiled tubing 12)
therethrough.
[0019] During the wellbore intervention operation, fluid may be
pumped through the internal passage 11 in the intervention pipe
(e.g., coiled tubing 12) and returned to the surface in the annulus
13. The annular sealing device 14 has a discharge line 16. In the
present example the discharge line 16 may be coupled to a debris
screening device 17 according to the invention. The debris
screening device 17 may include an inlet control valve 20 that can
be closed to stop all flow to the device 17. The debris screening
device 17 may be divided into three operating sections 1, 2, 3. The
first operating section 1 may be coupled to the discharge line 16
by an inlet manifold 24 that divides flow from the discharge line
16 to the three operating sections 1, 2, 3. The first operating
section 1 may include a first screening device 18, and may be
controllably sealed at its input end and output end by valves V1,
V2, V6, V7. Correspondingly, the second operating section 2 may
include a second, similarly configured screening device 22,
controllably sealed at its input and output ends by valves V3, V4,
V8 and V9, respectively. The purposes for including double valves
on each of the input and output of the first screening device 18
and the second screening device 22 is to enable maintaining the
contents of each screening device at a selected pressure while
disassembling the respective screening device from the debris
catcher 17, and to enable safe bleed off of pressure from the
respective screening section when removed from the debris catcher
17 prior to opening the screening section.
[0020] The third operating section 3 may be optionally provided for
safety purposes and include a valve V5 that can be opened in the
case the screening sections 18, 22 both become inoperable for any
reason or the pipe operation is in a section of the well where
cuttings collection and analysis is not necessary. Alternatively,
valve V5 in operating section 3 may be omitted or may be normally
open, and a burst disk 32 may be included in section 3 so that in
the event the screening pressure becomes excessive, the burst disk
32 will rupture, enabling fluid passage through section 3 before
pressure caused failure of either screening section 18, 22 may
occur. The burst disk 32 could also be included in either or both
screening sections.
[0021] The flow out of the three operating sections 1, 2, 3 is
coupled by an output manifold 26. The output manifold 26 may be
coupled to a fixed, manually operable or automatically operable
choke 28, that restricts flow out the annulus 13 to a maintain a
selected pressure therein. Output of the choke 28 is coupled to a
pressure tank 30 of any type known in the art.
[0022] During ordinary operation of the system shown in FIG. 1,
flow may be conducted through the first screening device 18 and
stopped from the second screening device by suitable operation of
the valves V1, V2, V6, V7. Pressure at the input and output of the
first screening device 18 may be measured by suitably disposed
pressure sensors or gauges P1, P2. After a selected time, or when
the differential pressure across the first screening device 18
(e.g., as measured by gauges P1, P2) reaches a selected threshold,
the valves V1, V2, V6, V7 may be operated to divert flow from the
discharge line 16 to the second screening section 22 and to isolate
the first screening section 18. The first screening section 18 may
then be opened, and debris, cuttings, etc. may be removed therefrom
and characterized as appropriate for the well intervention
operation being performed.
[0023] After a selected time, or when the differential pressure,
e.g., as measured by gauges P3 and P4, across the second screening
section 22 reaches a selected threshold, the valves V3, V4, V8, V9
may be operated to isolate the second screening section 22, and
return flow to the first screening section 18 by opening valves V1,
V2, V6, V7.
[0024] If any hazards or problems occur during operating the first
18 and second 22 screening sections, flow from the annulus 13 may
be diverted through the third operating section 3, and the
screening sections 18, 22, may be isolated by suitable operation of
the valves and opening valve V5.
[0025] In the present example, suitable sensors S1 and S2 may be
provided for the respective screening sections 18, 22 to enable
characterization of the debris trapped in the respective screening
section without the need to open the screening section. Such
sensors may include, without limitation, induction resistivity,
nuclear magnetic resonance relaxation time distribution, acoustic
velocity, density and neutron porosity. Such sensors are intended
to enable characterization of the debris according to particle
shape and size, particle composition and analysis of fluids flowing
through the screening sections (e.g., gas, oil, water and relative
fractions thereof).
[0026] Each screening section may include screens having at least
two or variable mesh sizes to enable capture larger amounts of
various size particles between screening section cleanings.
[0027] In some examples, the screening sections may be configured
to dump cuttings automatically. The depth of the wellbore may be
recorded automatically at the time of dumping to enable making a
record of depth with respect to cuttings dump.
[0028] A wellbore discharge screening device according to the
invention may enable more frequent characterization of the debris
leaving a wellbore during controlled annulus pressure drilling or
intervention operations than using only a pressure tank as is known
in the art prior to the present invention.
[0029] While the invention has been described with respect to a
limited number of embodiments, those skilled in the art, having
benefit of this disclosure, will appreciate that other embodiments
can be devised which do not depart from the scope of the invention
as disclosed herein. Accordingly, the scope of the invention should
be limited only by the attached claims.
* * * * *