U.S. patent application number 17/074065 was filed with the patent office on 2021-05-27 for systems and methods for managing debris in a well.
The applicant listed for this patent is SPOKED SOLUTIONS LLC. Invention is credited to Bryce Elliott Randle.
Application Number | 20210156230 17/074065 |
Document ID | / |
Family ID | 1000005374326 |
Filed Date | 2021-05-27 |
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United States Patent
Application |
20210156230 |
Kind Code |
A1 |
Randle; Bryce Elliott |
May 27, 2021 |
SYSTEMS AND METHODS FOR MANAGING DEBRIS IN A WELL
Abstract
Various systems, methods, and devices are disclosed for handling
contaminants in a wellbore or riser. A washpipe debris trap (WPDT)
traps contaminants traveling up a wellbore from a downhole
location, and the WPDT may serve as an indicator for a breached
screen in a downhole location. A marine riser reversing tool (MRRT)
may reverse the flow of fluid between a workstring conduit and an
annulus between the workstring and the wellbore such that fluid
rises to the wellhead with greater velocity. A bi-directional
chamber trap (BDCT) may be utilized in a wellbore operation to
remove contaminants from a fluid.
Inventors: |
Randle; Bryce Elliott;
(Highlands Ranch, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SPOKED SOLUTIONS LLC |
Houma |
LA |
US |
|
|
Family ID: |
1000005374326 |
Appl. No.: |
17/074065 |
Filed: |
October 19, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16162087 |
Oct 16, 2018 |
10808500 |
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17074065 |
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15714207 |
Sep 25, 2017 |
10100615 |
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16162087 |
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14926326 |
Oct 29, 2015 |
10669815 |
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15714207 |
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62398876 |
Sep 23, 2016 |
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62073572 |
Oct 31, 2014 |
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62203476 |
Aug 11, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 2200/04 20200501;
E21B 17/006 20130101; E21B 43/04 20130101; E21B 21/001 20130101;
E21B 43/267 20130101; E21B 37/08 20130101; E21B 34/06 20130101;
E21B 21/12 20130101; E21B 27/005 20130101; E21B 37/00 20130101;
E21B 43/08 20130101; E21B 34/08 20130101; E21B 43/045 20130101;
E21B 43/26 20130101; E21B 21/01 20130101 |
International
Class: |
E21B 37/08 20060101
E21B037/08; E21B 27/00 20060101 E21B027/00; E21B 21/00 20060101
E21B021/00; E21B 34/08 20060101 E21B034/08; E21B 21/12 20060101
E21B021/12; E21B 34/06 20060101 E21B034/06; E21B 37/00 20060101
E21B037/00; E21B 43/04 20060101 E21B043/04; E21B 43/08 20060101
E21B043/08; E21B 17/00 20060101 E21B017/00; E21B 21/01 20060101
E21B021/01 |
Claims
1. A device for trapping debris, comprising: a lower assembly
having a lower screen and a check valve, wherein the lower screen
is a thru-tubing screen; an upper assembly having an upper screen
and a check valve, wherein the upper screen is a thru-tubing
screen, and wherein the check valve of the upper assembly is a ball
check valve having a ball with a first density that is buoyant when
submerged in fluid having a second density, wherein the second
density is larger than the first density; an assembly bridge formed
between the lower assembly and the upper assembly; and wherein the
check valve of the lower assembly is a ball check valve that is
closed when the fluid flows in a forward direction, allowing only
the fluid and debris smaller than a gauge of the thru-tubing screen
of the lower assembly to leave the assembly bridge, and open when
the fluid flows in a reverse direction, allowing the fluid and
debris to enter the assembly bridge.
2. The device of claim 1, wherein the ball check valve of the upper
assembly is open when the fluid flows in a forward direction,
allowing the fluid and debris to enter the assembly bridge, and
closed when the fluid flows in a reverse direction, allowing only
the fluid and debris smaller than a gauge of the thru-tubing screen
of the upper assembly to leave the assembly bridge.
3. The device of claim 1, wherein the lower screen and the upper
screen have a substantially similar gauge.
4. The device of claim 1, wherein the upper assembly is arranged
along a first axis and the fluid flows in the forward direction
through upper assembly in a first direction, and the lower assembly
is arranged along a second axis and the fluid flows in the forward
direction through the lower assembly in a second direction.
5. The device of claim 4, wherein the first axis and the second
axis are substantially parallel, and the first direction and the
second direction are oriented in opposing directions.
6. The device of claim 1, wherein the lower assembly, the upper
assembly, and the assembly bridge, and positioned in a deck crate
having predetermined dimensions.
7. The device of claim 1, wherein the upper assembly is secured to
the deck crate with first securing means, and the lower assembly is
secured to the deck crate with second securing means.
8. The device of claim 1, wherein the assembly bridge comprises: a
first bridge sub having a first drain plug that is selectively
removable from the first bridge sub to allow the removal of
contents from the assembly bridge, and a second bridge sub having a
second drain plug that is selectively removable from the second
bridge sub to allow removal of contents from the assembly
bridge.
9. The device of claim 8, wherein first bridge sub interconnects to
the second bridge sub, and the first and second bridge subs are
configured to direct the fluid flowing in the forward direction
from a first direction to a second direction.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/162,087, filed Dec. 16, 2018, which is a
continuation of U.S. patent application Ser. No. 15/714,207, filed
Sep. 25, 2017, which claims the benefit of U.S. Provisional Patent
Application Ser. No. 62/398,876, filed Sep. 23, 2016, and U.S.
patent application Ser. No. 15/714,207 is a continuation-in-part of
U.S. patent application Ser. No. 14/926,326, filed Oct. 29, 2015,
which claims the benefit of U.S. Provisional Patent Application
Ser. No. 62/073,572, filed Oct. 31, 2014, and U.S. Provisional
Patent Application Ser. No. 62/203,476, filed Aug. 11, 2015, all of
which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to several novel tools useful
in the field of drilled wells, particularly in the areas of
cleaning operations, sand control operations and debris and trash
management measures.
BACKGROUND
[0003] Various types of debris or other undesirable materials are
produced during the drilling, completion, production, intervention,
and workovers of drilled wells. These materials, if not adequately
managed, can cause various issues, spanning from decreasing the
efficiency of well operations to complete loss of a well.
[0004] When debris is pumped or introduced to a drilling rig
circulation system, such debris or trash has the potential to
become lodged in downhole equipment utilized during drilling,
intervention, workover, or completion causing sub-satisfactory
performance or failure. In addition, downhole production equipment
may also be impaired or restricted to future access.
[0005] Examples of debris or trash include, but are not limited to
tools, paint chips, personal safety equipment, pipe dope, metal
shavings, rust, fibers, precipitated fluid chemicals, mud, or
formations. Any of the previously mentioned examples of debris have
the potential to reduce performance or failure in surface or
downhole equipment.
[0006] Traditional circulation filtration systems filter at low
pressure, are comprised of settling tanks and pumps, or utilized a
filtration medium such as diatomaceous earth or absolute filtration
layers to remove undesirables from fluid systems. Most of these
circulation systems focus on the cleanliness of fluid as it exits a
well, only permits flow in one direction, requires manning by third
party personnel, and negates contamination points between its
discharge and well entry points.
[0007] Additionally, drilled wells that penetrate soft rock
formations, typically located in offshore environments, often
produce formation sand resulting in significant damage to wellbore
equipment, surface facilities, and infrastructure utilized to
transport hydrocarbon to commercial terminals. Well known industry
sand control methods such as gravel packing or hydraulic fracturing
are utilized to immobilize the formation sand and increase the
productivity of wells. The methods utilize a combination of sand
control screens and sand control tools to place uniquely sized
proppant based on formation particle sized distribution to act as a
filter and achieve the immobilization.
[0008] The operation of placing the uniquely sized proppant
successfully relies on a sand control service tool being in the
correct position, the integrity of a crossover port surviving the
operation, and the integrity of sand control screens surviving
deployment and the proppant placement operation.
[0009] Although methods to correctly identify tool placement and
maintaining the desired placement throughout pumping operations has
been battled and advances have been made on shelf wells, the
ability to maintain and verify tool position becomes increasingly
more difficult due to the existence of smaller companies utilizing
older technology and new exploration reaching increasing farther
depths. The consequence of a tool being in the incorrect position,
or being pumped out of position, is proppant reaching the annular
space above the sand control packer between the casing and the
workstring/service tool assembly.
[0010] The failure of crossover port integrity is often attributed
to erosion created by the properties and volumes of proppant placed
during an operation. Reaching into the hundreds of thousands of
pounds of proppant and sometimes into the millions, this failure
exposes the gundrill ports of the crossover tool and subsequently
the washpipe or annular space above the sand control packer between
the casing and the workstring/service tool assembly to
proppant.
[0011] Typically resulting in sticking the sand control service
tool, the above failures are potentially recovered from through
various recovery operations but may result in the loss of the
target zone. An integrity breach of sand control screens also
results in proppant reaching the annular space above the sand
control packer between the casing and the workstring/service tool
assembly, however, it bears the added consequence of proppant
sticking to the inner string conduit (often referred to as
washpipe) across the sand control interval, complete loss of sand
control integrity, increased sand production and costs associated
with handling/disposal at the surface, and potential loss of the
well. It is this mode of failure that has the potential to go
unrealized until a well is brought into production.
[0012] Aside from eliminating the potential for sticking the sand
control service tool, it would be significantly desirable to know
if sand control screen integrity exists prior to running the
production tubing or moving off of location with the rig.
[0013] In addition to debris in the form of sand and misplaced
proppant, drilling fluid and other materials pumped into the well
may pose a threat to operations under certain circumstances. Riser
pipes are used to connect a well at the seabed to a rig. In some
cases, such as with a compliant tower, the riser is utilized to
connect the subsea wellhead or subsea tree to a platform. In
deepwater, the cold seawater temperature can cause congealing of
the drilling fluid, such as mud, or precipitation of brine within
the riser pipe. The larger internal diameter of riser in relation
to its pressure ratings and optimum pump rate abilities of the rig
typically lead to an insufficient ability to achieve the turbulent
flow and annular velocities required to clean, displace, and carry
all of the existing debris, congealed fluid, etc. from the pipe.
Consequently, it can take several staged treatments and multiple
days, depending on seabed depth, to successfully clean and displace
riser to a suitable fluid for operations to proceed.
SUMMARY OF THE INVENTION
[0014] The present invention relates generally to three tools
utilized to manage debris and other undesirable material in a well
system. Such management can be carried out through the filtering of
fluid being pumped into a well, ensuring integrity of sand control
systems, and ensuring riser pipe and other surfaces are clean of
debris and other material.
[0015] One aspect of the present invention relates generally to an
apparatus and method for filtering solid debris from surface and
wellbore fluid systems. There is a need for a low level filtration
system that resides within a rig's circulation infrastructure that
is capable of removing debris and trash encountered between
traditional systems and wellbore entry points. In particular, but
not exclusively, the invention relates to a tool for filtering
drilling stand pipe surface lines, surface storage systems,
drilling rig circulation systems, and wellbore systems that fluid
passes through during drilling, interventions, and
completion/workovers of offshore and land wells.
[0016] An objective of the invention is to provide an apparatus to
facilitate the passive removal of large and small debris and trash
such as tools, paint chips, personal safety equipment, pipe dope,
metal shavings, rust, fibers, precipitated fluid chemicals, mud, or
formations from a rig's circulation system. In addition, the
apparatus will be capable of receiving module adaptors that provide
increased levels of filtration, fluid shearing abilities, pressure
monitoring, and fluid properties.
[0017] Another objective of the invention is to permit the change
out of filters or modules without the need to execute additional
surface line pressure tests to requalify the system for operations
with working pressure ratings equal to the system it has been
integrated with.
[0018] A further objective is to permit filtering of the rig's
circulation system for fluids both entering and exiting the well
without the need for reconfiguration or a dedicated operator. The
horizontal parallel design with offset entry/exit points, baffling,
and debris fluidization system allow the system to operate
continuously while simultaneously removing filter mediums and
modules or transferring captured debris.
[0019] An apparatus of this nature may provide the following
benefits: filtering mediums with direction preferred fluid check
devices to permit filtering and flow in multiple directions; a
means to divert fluid flow to permit continuous operation while
inspecting or reconfiguring modules; an internal system for
fluidizing fine debris material and transferring it to a rig
disposal system; a pressure rating equal to or in excess of the
rigs circulating system pressure rating; and a pressure indicator
to alarm of large debris capturing.
[0020] Another aspect of the present invention relates to an
apparatus and method for cleaning the internal surface of pipes. In
particular, but not exclusively, the invention relates to a tool
for, and a method of, cleaning the internal surface of riser pipes
used for drilling, interventions, completion, and workovers of
offshore wells. The apparatus warrants the forward circulation of
the marine riser, but permits pumping down the workstring. Unlike
traditional tools utilized for wellbore and riser cleaning, the
apparatus diverts the flow from the workstring, allowing treatment
fluids to be placed in direct contact with the riser and isolates
the treatment with a sealing element. Returns are received in the
annulus above the sealing element and are then handled on surface.
The flow path of the apparatus, thus addresses common concerns with
cleaning risers that include but are not limited to lift velocity,
chemical volume, riser pressure ratings, slip-joint pack-off
ratings, surface filtration capacity, and rig time.
[0021] An objective of the invention is to provide an apparatus to
facilitate the removal of congealed drilling fluid such as mud or
brine from within a marine riser internal diameter and the
associated equipment in line with the riser such as blow out
preventers.
[0022] Another objective of the invention is to aid in lift
velocity by utilizing flow paths other than the traditional flow
paths typically used to clean pipe body internal diameters,
completely eliminating the requirement of high annular
velocities.
[0023] A further objective is to minimize applied pressure to the
internal diameter of the marine riser which traditionally is a
limiting factor in achieving optimal cleaning efficiency. This will
ultimately reduce risks associated with mechanical failure of
associated equipment and increase efficiency of surface operations
such as filtering.
[0024] An apparatus of this nature may provide the following
benefits: contain a sealing element to create a workstring/marine
riser annulus; be capable of seamlessly integrating into currently
existing wellbore cleanout tool system technology; utilize the
smaller workstring internal diameter as the lifting conduit, thus
increasing lift velocity; be capable of proper operating pressures
to achieve proper clean-up irrespective of seabed depth; aid in
debris removal by allowing blow out preventers to be functioned
while cleaning; clean above tree plugs and run an impression block
downhole before running subsea test trees; and aid in greener open
water riser clean-ups.
[0025] Another aspect of the present invention relates to sand
control failure mitigation and identification for sand control
operations conducted in wells requiring inner string conduits and,
in particular, a method to identify sand control screen failure or
sand control tool failure when service tools and inner string
conduits are retrieved at surface.
[0026] An objective of the invention is to provide an apparatus to
eliminate sand from reaching the annular space above the sand
control packer between casing and the workstring/service tool
assembly.
[0027] Another objective of the invention is to trap proppant in
the washpipe and to prevent it from reaching the annular space
above the sand control packer between the casing and
workstring/service tool assembly when a breach occurs via the sand
control screens or crossover port body.
[0028] A further object is to provide an indicator for the operator
or sand control company to identify and confirm an integrity breach
in the sand control hardware prior to demobilizing costly equipment
from location or bringing the well onto production.
[0029] A further object is to provide an apparatus that is cost
efficient, adjustable to the selected sand control design, and
integrates seamlessly. One advantage of the invention lies in a
simple, low cost solution to the potential detriment of a
reservoir, wellbore, platform processing equipment, and/or
pipelines.
[0030] A further object is to provide other applications of the
present invention, including the Marine Riser Reversing Tool
(MRRT). For example, embodiments of the present invention may be
capable of through-tubing operations on multiple workstring sizes
inclusive of coil tubing. In addition, embodiments of the present
invention may be capable of coil tubing operations for fluid
manipulation. Lastly, embodiments of the present invention may be
capable of wire line or electric line deployment and placement for
permanent and semi-permanent installation.
[0031] One particular embodiment of the present invention is a
system for cleaning an annulus in a wellbore or riser, comprising a
workstring comprising a plurality of drill pipe positioned in a
wellbore or riser, the plurality of drill pipe form a conduit for a
fluid to flow through the workstring, and an outer diameter of the
plurality of drill pipe and an inner diameter of the wellbore or
riser form an annulus for the fluid to flow through; a reversing
tool positioned in the workstring, the reversing tool having a body
with a bottom end and a top end, a first channel in fluid
communication with the conduit at the top end and the annulus at
the bottom end, and a second channel in fluid communication with
the annulus at the top end and the conduit at the bottom end; and a
debris trap positioned in the workstring, the debris trap having an
upper assembly, a lower assembly, and a chamber formed between the
upper assembly and the lower assembly, the upper assembly
comprising an upper screen, and the lower assembly comprising a
lower screen and a check valve.
[0032] Various embodiments of the system for cleaning an annulus in
a wellbore or riser may further comprise a blow out preventer
positioned in the wellbore or riser, the reversing tool and the
debris trap are positioned above the blow out preventer in the
wellbore or riser. Embodiments may further comprise a control
screen positioned between the conduit of the plurality of drill
pipe and the annulus between the plurality of drill pipe and the
wellbore or riser, the control screen is configured to filter
contaminants from the fluid flowing between the annulus and the
conduit. In various embodiments, the control screen, the upper
screen, and the lower screen have a substantially similar gauge
size. Embodiments may further comprise a washpipe positioned in the
workstring, the washpipe forms a lower terminus of the conduit, and
the debris trap is positioned in the washpipe. In some embodiments,
a cross sectional area of the annulus formed between the plurality
of drill pipe and the wellbore or riser may be larger than a cross
sectional area of the conduit of the plurality of drill pipe. In
various embodiments, the reversing tool further may comprise a
seal, and an outer diameter of the seal is larger than an outer
diameter of the body of the reversing tool.
[0033] In some embodiments, the first channel extends between a
first opening at the top end and a second opening at the bottom end
and the second channel extends between a first opening at the
bottom end and a second opening at the top end, cross sectional
areas of the second openings of the first and second channels are
larger than cross sectional areas of the first openings of the
first and second channels. In some embodiments, the second openings
of the first and second channels comprise at least one of a chamfer
and a round. Embodiments may further comprise a second seal
positioned proximate to the first seal, each seal comprises a cup
retainer and a cup seal, and a spacer sleeve is positioned between
the seals. In various embodiments, the first channel and the second
channel are substantially straight.
[0034] In some embodiments, the lower screen of the lower assembly
is a thru-tubing screen, and the upper screen of the upper assembly
is a thru-tubing screen, and the upper assembly comprises a bull
plug. In various embodiments, the check valve of the lower assembly
is a ball check valve that is open when the fluid flows in a
forward direction, allowing the fluid and debris to enter the
chamber, and closed when the fluid flows in a reverse direction,
allowing only the fluid and debris smaller than a gauge of the
thru-tubing screen of the lower assembly to leave the chamber. In
some embodiments, the debris trap is positioned in the workstring
below the reversing tool, the fluid flows through the lower
assembly, the chamber, and then the upper assembly of the debris
trap. In various embodiments, the debris trap is positioned in the
workstring above the reversing tool, the fluid flows through the
lower assembly, the chamber, and then the upper assembly of the
debris trap.
[0035] In some embodiments, the fluid flows through the lower
assembly of the debris trap, the chamber of the debris trap, and
the upper assembly of the debris trap, the fluid has a first
density; and the lower screen of the lower assembly is a
thru-tubing screen, and the upper screen of the upper assembly is a
thru-tubing screen, and the upper assembly comprises a ball check
valve having a ball with a second density, the second density is
less than the first density. In some embodiments, the check valve
of the lower assembly is a ball check valve that is closed when the
fluid flows in a forward direction, allowing allow only the fluid
and debris smaller than a gauge of the thru-tubing screen of the
lower assembly to leave the chamber, and open when the fluid flows
in a reverse direction, allowing the fluid and debris to enter the
chamber; and the ball check valve of the upper assembly is open
when the fluid flows in a forward direction, allowing the fluid and
debris to enter the chamber, and closed when the fluid flows in a
reverse direction, allowing allow only the fluid and debris smaller
than a gauge of the thru-tubing screen of the upper assembly to
leave the chamber. In various embodiments, the debris trap is
positioned in the workstring below the reversing tool, the fluid
flows through the lower assembly, the chamber, and then the upper
assembly of the debris trap. In some embodiments, the debris trap
is positioned in the workstring above the reversing tool, the fluid
flows through the lower assembly, the chamber, and then the upper
assembly of the debris trap.
[0036] Another particular embodiment is a device for reversing
fluid flow in a drillstring, comprising a body extending between a
top end and a bottom end, the body having a longitudinal axis, the
body having a conduit cross sectional area disposed about the
longitudinal axis and extending between the top end and the bottom
end, and the body having an annular cross sectional area disposed
about the conduit cross sectional area and extending between the
top end and the bottom end; a first channel in the body, the first
channel extending between the conduit cross sectional area at the
top end and the annular cross sectional area at the bottom end; a
second channel in the body, the second channel extending between
the annular cross sectional area at the top end and the conduit
cross sectional area at the bottom end; and a seal positioned on
the body, an outer diameter of the seal is larger than an outer
diameter of the body.
[0037] In some embodiments, the first channel extends between a
first opening at the top end and a second opening at the bottom
end, and the second channel extends between a first opening at the
bottom end and a second opening at the top end, cross sectional
areas of the second openings of the first and second channels are
larger than cross sectional areas of the first openings of the
first and second channels. In various embodiments, the second
openings of the first and second channels comprise at least one of
a chamfer and a round. Embodiments may further comprise a second
seal positioned proximate to the first seal, each seal comprises a
cup retainer and a cup seal, and a spacer sleeve is positioned
between the seals. In various embodiments, the first channel and
the second channel are substantially straight. In some embodiments,
the annular cross sectional area is larger than the conduit cross
sectional area.
[0038] A further particular embodiment of the present invention is
a device for trapping debris, comprising a lower assembly having a
lower screen and a check valve, the lower screen is a thru-tubing
screen; an upper assembly having an upper screen and a bull plug,
the upper screen is a thru-tubing screen; and a chamber formed
between the lower assembly and the upper assembly.
[0039] In some embodiments, the check valve is a ball check valve
that is configured to open when a fluid flows in a forward
direction, allowing the fluid and debris to enter the chamber, and
is configured to close when the fluid flows in a reverse direction,
allowing only the fluid and debris smaller than a gauge of the
thru-tubing screen of the lower assembly to leave the chamber. In
various embodiments, the lower screen and the upper screen have a
substantially similar gauge.
[0040] Another particular embodiment of the present invention is a
system for trapping debris, comprising a lower assembly having a
lower screen and a check valve, the lower screen is a thru-tubing
screen; an upper assembly having an upper screen and a check valve,
the upper screen is a thru-tubing screen, and the check valve of
the upper assembly is a ball check valve having a ball with a first
density that is buoyant when submerged in fluid having a second
density, wherein the second density is larger than the first
density; a chamber formed between the lower assembly and the upper
assembly.
[0041] In some embodiments, the check valve of the lower assembly
is a ball check valve that is closed when the fluid flows in a
forward direction, allowing the fluid and debris smaller than a
gauge of the thru-tubing screen of the lower assembly to leave the
chamber, and open when the fluid flows in a reverse direction,
allowing the fluid and debris to enter the chamber. In various
embodiments, the ball check valve of the upper assembly is open
when the fluid flows in a forward direction, allowing the fluid and
debris to enter the chamber, and closed when the fluid flows in a
reverse direction, allowing only the fluid and debris smaller than
a gauge of the thru-tubing screen of the upper assembly to leave
the chamber. In some embodiments, the lower screen and the upper
screen have a substantially similar gauge.
I. BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1A is a diagram showing incorporation of the
Bi-Directional Chamber Trap (BDCT), Marine Riser Reversing Tool
(MRRT), and Washpipe Debris Trap (WPDT) into a well system in one
embodiment of the present invention.
[0043] FIG. 1B is a diagram showing the position of the MRRT and
the WPDT relative to a blow out preventer in a well system in one
embodiment of the present invention.
[0044] FIG. 2A is a cross-sectional view of a lower assembly of the
WPDT in one embodiment of the present invention.
[0045] FIG. 2B is a cross-sectional view of an upper assembly of
the WPDT in one embodiment of the present invention.
[0046] FIG. 3 is a cross-sectional view of the WPDT during a sand
control job in one embodiment of the present invention.
[0047] FIG. 4 is a cross-sectional view of the WPDT during a breach
of the cross over tool in a sand control job in one embodiment of
the present invention.
[0048] FIG. 5A is a cross-sectional view of the WPDT in a reversed
position performing the role of a downhole BDCT in one embodiment
of the present invention.
[0049] FIG. 5B is a cross-sectional view of the WPDT being used in
conjunction with the MRRT in one embodiment of the present
invention.
[0050] FIG. 6A is a cross-sectional view of a Drillpipe Debris Trap
In-Line Filter (DPDT) in one embodiment of the present
invention.
[0051] FIG. 6B is a front elevation view of a DPDT in another
embodiment of the present invention.
[0052] FIG. 6C is another front elevation view of the DPDT of the
embodiment in FIG. 6B.
[0053] FIG. 6D is yet another front elevation view of the DPDT of
the embodiment in FIG. 6B.
[0054] FIG. 6E is a side elevation view of the DPDT of the
embodiment in FIG. 6B.
[0055] FIG. 6F is a bottom plan view of the DPDT of the embodiment
in FIG. 6B.
[0056] FIG. 6G is a perspective view of the DPDT of the embodiment
in FIG. 6B.
[0057] FIG. 6H is a top plan view of the DPDT of the embodiment in
FIG. 6B.
[0058] FIG. 7 is a detailed, cross-sectional view of the MRRT in
one embodiment of the present invention.
[0059] FIG. 8A is a cross-sectional view of the MRRT during a riser
cleaning job in one embodiment of the present invention.
[0060] FIG. 8B is a detailed cross sectional view of the MRRT
during a riser cleaning job in one embodiment of the present
invention.
[0061] FIG. 9 is a cross-sectional view of the MRRT in one
embodiment of the present invention.
[0062] FIG. 10 is a cross-sectional view of the MRRT with a return
adapter in one embodiment of the present invention.
[0063] FIG. 11 is a detailed, cross-sectional view of the BDCT in
one embodiment of the present invention.
[0064] FIG. 12A is a schematic diagram of a single BDCT system in
one embodiment of the present invention.
[0065] FIG. 12B is a schematic diagram of a parallel BDCT system in
one embodiment of the present invention.
II. DETAILED DESCRIPTION
[0066] It is to be understood that the following disclosure
provides many different embodiments, or examples, for implementing
different features of various embodiments. Specific examples of
components and arrangements are described below to simplify the
disclosure. These are, of course, merely examples and are not
intended to be limiting. In addition, the disclosure may repeat
reference numerals and/or letters in the various examples. This
repetition is for the purpose of simplicity and clarity and does
not in itself dictate a relationship between the various
embodiments and/or configurations discussed.
[0067] As used herein, the terms "couple," "coupling," "coupled,"
"coupled together," and "coupled with" are used to mean "directly
coupled together" or "coupled together via one or more elements".
As used herein, the terms "up" and "down"; "upper" and "lower";
"top" and "bottom"; and other like terms indicating relative
positions to a given point or element are utilized to more clearly
describe some elements. Commonly, these terms relate to a reference
point as the surface from which drilling operations are initiated
as being the top point and the total depth being the lowest point,
wherein the well (e.g., wellbore, borehole) is vertical, horizontal
or slanted relative to the surface. It will also be appreciated by
one skilled in the art that the inventions described herein may
apply to various types of tubulars well known in the art for both
off and on shore rigs. Accordingly, as used herein, the terms
"drill pipe," "washpipe," and "tubing" may be used interchangeably
where appropriate. Further, the terms "casing" and "riser" may be
used interchangeably where appropriate.
[0068] Generally, the term "tubular" may be used to refer to a
liner, a casing, a washpipe, a drillpipe, or another other long,
hollow, substantially-cylindrical structure. The present invention
may be used with various types of tubulars. Accordingly, the terms
"washpipe," "washpipe pup," "liner," "tubing," "drillpipe," and
"casing" may be used interchangeably. Further, it is expressly
understood that although the figures depict only certain types of
tubulars, the invention is not limited to these embodiments.
[0069] In a preferred embodiment of the present invention, an
improved well system and method of operating the well system is
provided by the incorporation of novel tools: the Washpipe Debris
Trap (WPDT), the Debris Trap In-Line Filter (DPDT), the Marine
Riser Reversing Tool (MRRT), and the Bi-Directional Chamber Trap
(BDCT). As will be appreciated by one skilled in the art, the three
tools integrate seamlessly into prior art well systems, such as the
well systems shown in FIGS. 1 and 6, to provide improved down hole
cleaning processes, improved monitoring of sand control system
integrity, and improved filtration of fluid entering and exiting
the well.
[0070] Several configurations of the three tools can be utilized in
a well system. FIG. 1A depicts one embodiment of the system
incorporating three tools, with the MRRT and WPDT being positioned
above the Blow Out Preventers (BOP). FIG. 1B depicts yet another
embodiment of the system where the MRRT and WPDT are positioned
below the BOPs 30. Referring back to FIG. 1A, it will be
appreciated that the MRRT 29, BDCT 26, and WPDT 32 can be
incorporated into prior art well systems. The manner in which the
MRRT, BDCT, and WPDT incorporate into and function within a well
system is more fully described below.
[0071] It will further be appreciated that different combinations
of one or more MRRT, BDCT, and/or WPDT will be utilized by various
embodiments of the present invention. For example, in one
embodiment of the invention, the MRRT and WPDT may utilized in
conjunction with one another to facilitate interval specific
wellbore clean out in a well system, such as across the BOP, gas
lift mandrels, or chemical injection mandrels. In another
embodiment of the present invention, the WPDT may be utilized with
one or more BDCTs in order to provide a last line of defense
against debris being pumped into and out of a well system, which
would potentially damage sensitive well equipment. In yet another
embodiment of the present invention, the MRRT may be utilized in
conjunction with currently existing tools to minimize annular fluid
loss when a formation is exposed. It will be appreciated that other
combinations exist, and the above disclosure is for the purpose of
example only.
[0072] A. Washpipe Debris Trap
[0073] The Washpipe Debris Trap (WPDT) aspect of the present
invention may be used in systems and methods for drilling and
completion of wells. Some embodiments of the WPDT may be
particularly useful in drilled wells in offshore environments and
other environments where formation sand production is prevalent,
however it will be appreciated by one skilled in the art that use
of the WPDT will be beneficial in any environment where proppant,
debris of a granular nature, or formation sand is present and/or
sand control measures are being taken.
[0074] In a preferred embodiment of the present invention, the WPDT
serves as an indicator of a sand control system integrity breach
during a sand control job by trapping sand that has breached sand
control measures as it moves into the WPDT and up the washpipe
towards the crossover tool. The WPDT provides the additional
benefit of preventing sand that has breached the sand control
screens from traveling up the washpipe through the crossover tool
and reaching the annular space above the sand control packer
between the casing and the workstring/service tool assembly. It
will be appreciated that use of some embodiments of the WPDT will
both indicate that a breach has occurred and will mitigate damage
resulting from such breach until such breach can be remedied.
[0075] Referring now to FIGS. 2A and 2B, in a preferred embodiment
of the present invention, WDPT 32 is comprised of upper assembly 72
and lower assembly 71. In this embodiment, upper assembly 72 is
comprised of screen 73, bull plug 76, and 3-way adapter 75. In a
preferred embodiment, screen 73 is a thru-tubing screen that is of
an appropriate size, diameter, tensile, burst, collapse, and gauge
to be placed within washpipe pup 80, such as the DeltaPore HP.TM.,
manufactured by Delta Screens. Bull plug 76 is coupled to one end
of screen 73 through standard coupling means, such as threading. A
bull plug is well known in the art, such as the Mayco bull plug.
3-way adapter 75 contains three coupling locations: an inner
coupling location 88, a screen-facing outer coupling location 89,
and a non-screen-facing outer coupling location 90. In some
embodiments of the present invention coupling locations 88-90 will
be a Hydrill 511 box/pin coupling. It will be appreciated by those
skilled in the art that other embodiments will use other coupling
means. Inner coupling location 88 of 3-way adaptor 75 is coupled to
the end of screen 73 that is not coupled to bull plug 76. 3-way
adapter 75 also provides a means to couple a washpipe pup 80 to
either or both of screen-facing 89 and non-screen facing 90 outer
couplings. In a preferred embodiment, 3-way adapter 75 is
constructed of fairly hard material with some corrosion resistance
which is readily machineable, such as A519-4140 in grade P110. It
will be appreciated that other satisfactory materials exist and can
be used to construct 3-way adapter 75.
[0076] In a preferred embodiment, lower assembly 71 is comprised of
screen 91, 3-way adapter 92, and ball check valve 74. Screen 91 and
3-way adapter 92 of lower assembly 71 may be identical to those of
upper assembly 72 in some embodiments. In other embodiments, they
may be of different sizes or dimensions. In a preferred embodiment,
ball check valve 74 may be comprised of ball 93 which is of very
hard and corrosion resistant material, valve body 94, and ball
keeper pin 95. In the preferred embodiment, valve body 94 will be
made from A519-4140 in grade P110. It will be appreciated that
other satisfactory materials exist and can be used to construct the
valve body. The inclusion of ball keeper pin 95 in ball check valve
74 allows ball 93 to be changed if necessary, thus prolonging the
life of ball check valve 74. In other embodiments, ball check valve
74 may be a Mingo Manufacturing ball check valve, or other
commercially available ball check valve. Ball check valve 74 is
coupled to one end of screen 91 of lower assembly 71 through
standard coupling means, such as threading. The other end of screen
91 is coupled to inner coupling location 88 of 3-way adapter 92 of
lower assembly 71. As disclosed above, washpipe pup 80 may be
coupled to either or both of screen-facing 89 and non-screen-facing
90 outer coupling locations of 3-way adapter 92. In a preferred
embodiment, washpipe pup 80 is coupled to screen-facing outer
coupling location 89 of both upper 72 and lower 71 assemblies,
creating an enclosed chamber 96 between lower 71 and upper 72
assemblies.
[0077] Referring now to FIG. 3, in a preferred embodiment of the
present invention, WPDT 32 is utilized in conjunction with a
crossover tool 79 on a sand control job in a wellbore. In this
embodiment, WPDT 32 is coupled to washpipe 81 located down well
from crossover tool 79 in the sand control bottom hole assembly,
and inside of sand control screen base pipes 97. It will be
appreciated that both a casing/sand control screen annulus 68 and a
sand control screen/washpipe annulus 69 exist in this
configuration.
[0078] Operation of WPDT 32 in a preferred embodiment is
demonstrated by flow path 77. During a gravel-pack operation or
other sand control jobs, proppant transport fluids are pumped down
workstring to crossover tool 79. Flow path 77 continues into the
crossover tool 79, where it is diverted into the casing/sand
control screen annulus 68. As proppant transport fluid enters the
casing/sand control screen annulus 68, proppant 67 does not pass
screen 70 (if performing correctly) and begins to stack up in
casing/sand control screen annulus 68. The gauge or micron size of
screen 70 is selected to allow transport fluid to pass through
while preventing proppant 67 from passing through. As proppant 67
continues to stack up, transport fluid flows through proppant 67
before flowing through screen 70 into sand control screen/washpipe
annulus 69. Once in sand control screen/washpipe annulus 69, flow
path 77 continues into WPDT 32 through screen 91 and ball check
valve 74 of lower assembly 71.
[0079] In a preferred embodiment of the present invention, WPDT 32
will be positioned so that lower assembly 71 is positioned at the
bottom of the sand control screen 70 to ensure an appropriate
return circulation point. Flow path 77 then continues through the
chamber 96 of WPDT 32 and out screen 73 of upper assembly 72 into
washpipe 81 and through the crossover tool 79. The gauge or micron
size of screens 73, 91 of the lower and upper assemblies are
preferably the same size as those of sand control screen 70 and/or
selected to allow fluid to pass through while preventing proppant
67 to pass through.
[0080] To the extent a breach of the sand control system occurs,
such as a breach of sand control screen 70, proppant 67 would then
enter sand control screen/washpipe annulus 69. Flow path 77 would
then carry proppant 67 into chamber 96 of WPDT 32 through ball
check valve 74 of lower assembly 71. Flow path 77 then carries
proppant 67 toward upper assembly 72, where proppant 67 would then
be separated from the transport fluid due to the gauge or micron
size of screen 73, in effect trapping proppant 67 inside chamber 96
of WPDT 32 between screens 73, 91 of upper 72 and lower 71
assemblies. Proppant 67 cannot pass back through screen 91 of the
lower assembly, and additionally cannot leave chamber 96 due to
ball check valve 74, which closes if there is a reverse flow or due
to gravity when the forward flow stops.
[0081] When the sand control workstring is retrieved from the well,
WDPT 32 can indicate whether a sand control breach exists. If there
is proppant 67 in chamber 96 of WPDT 32, this will indicate that a
breach may exist. Alternatively, if there is no proppant 67 in
chamber 96 of WPDT 32, no breach exists. Such early detection
allows a well operator to address the issue before more costly
damage is done. In some embodiments of the WPDT, a well operator
will be able to determine that WPDT 32 has trapped proppant 67 in
chamber 96 before retrieving the sand control workstring from the
well. For example, if there is a loss or reduction of fluid return
at the surface, the operator will know that WPDT 32 should be
returned to the surface to determine whether proppant 67 is trapped
in chamber 96, thus indicating a breach of the sand control
system.
[0082] Referring now to FIG. 4, in some embodiments of the present
invention, it will be appreciated that use of WPDT 32 will prevent
proppant 67 transport fluid from entering the sand control
screen/washpipe annulus 69 in the event of a crossover tool 79
failure. In the event of such a failure, proppant 67 will be
separated from transport fluid as the proppant transport fluid
travels down washpipe 81 and through screen 73 of upper assembly 72
of WPDT 32.
[0083] Referring now to FIGS. 5A and 5B, in yet another embodiment
of the present invention, WPDT 32 may be used as a filter further
up the workstring. In this embodiment, the WPDT is reversed such
that lower assembly 71 is further up the workstring than upper
assembly 72. In this embodiment, as fluid is pumped down the
workstring, the fluid will flow through screen 91 of lower assembly
71. Any proppant 67, debris, or other material larger than the
gauge of screen 91 of lower assembly 71 will pass through ball
check valve 74 of lower assembly 71. Once the material passes
through ball check valve 74 it will become trapped in chamber 96 of
WPDT 32, as it will not pass through screen 73 of upper assembly
72. Fluid and materials smaller than the gauge of screen 73 of
upper assembly 72 will continue to pass through WPDT 32 and down
the workstring. Such an embodiment provides at least the benefits
of preventing materials that would be harmful to downhole tools
from travelling further down the well, as well as providing an
indicator to the well operator that such materials are in the fluid
being pumped once WPDT 32 is retrieved from the well. Further, this
embodiment of the invention may be utilized as a space-saving
alternative to the BDCT (described below), which can be beneficial
to smaller offshore drilling rigs that do not have space available
to place a BDCT on the rig. It will be appreciated that in other
parts of the well or under specific conditions, MRRT 29 can behave
similarly to crossover tool 79, as depicted in FIG. 5B.
[0084] The WPDT may be used as a standalone in-line filter at any
depth within the well in any configuration with respect to the
upper and lower screen assemblies. The screens may be sized as
desired to accommodate the user's preference. Based on the
configuration, the WPDT can accept flow during forward and reverse
circulations. It may be inserted into any size workstring,
drillpipe, or coiled tubing to act as a downhole in-line filter for
fluid mediums passing through it.
[0085] The WPDT would be a space saving alternative for any surface
debris filtration unit or downhole debris filtration or capturing
tool. The two-piece design allows for customizable lengths and
provides an ability to carry debris out of the well within its trap
versus attempts to boost debris out of the well with varying
diameters and pump rates.
[0086] Alternative embodiments of the WPDT may be used at any point
in the systems described herein.
[0087] B. Debris Trap In-Line Filter (DPDT)
[0088] The Drillpipe Debris Trap In-Line Filter (DPDT) is an
alternative embodiment of the WPDT. The DPDT is a simple and
reliable in-line downhole debris capturing system that seamlessly
integrates into workstring configurations for filtering surface
and/or wellbore debris based on circulation path. In some
embodiments of the present invention, the DPDT is installed on the
deck of a drilling rig rather than downhole. This includes, but is
not limited to drilling rigs, drilling platforms, pads, production
facilities, workboats, ROV vessels, etc.
[0089] Referring now to FIG. 6A, in a preferred embodiment of the
present invention, DPDT 33 is comprised of upper assembly 228 and
lower assembly 232. In this embodiment, upper assembly 228 is
comprised of screen 236, ball check valve 240, and 3-way adapter
244. In a preferred embodiment, screen 236 is a thru-tubing screen
that is of an appropriate size, diameter, tensile, burst, collapse,
and gauge to be placed within washpipe pup, tubing, casing,
drillpipe, or other suitable conduit, such as the DeltaPore HP.TM.,
manufactured by Delta Screens, or any other conduit. 3-way adapter
244 contains three coupling locations: an inner coupling location
248, a screen-facing outer coupling location 252, and a
non-screen-facing outer coupling location 256. In some embodiments
of the present invention coupling locations 248, 252, 256 will be a
Hydrill 511 box/pin coupling. It will be appreciated by those
skilled in the art that other embodiments will use other coupling
means. Inner coupling location 248 of 3-way adaptor 244 is coupled
to the end of screen 236 that is not coupled to ball check valve
240. 3-way adapter 244 also provides a means to couple a washpipe
pup or other conduit to either or both of screen-facing 252 and
non-screen facing 256 outer couplings. In a preferred embodiment,
3-way adapter 244 is constructed of fairly hard material with some
corrosion resistance which is readily machineable, such as
A519-4140 in grade P110. It will be appreciated that other
satisfactory materials exist and can be used to construct 3-way
adapter 244. In a preferred embodiment, ball check valve 240 may be
comprised of ball 260 which is of very hard and corrosion resistant
material, valve body 264, and ball keeper pin 268.
[0090] In a preferred embodiment, lower assembly 232 is comprised
of screen 272, 3-way adapter 276, and ball check valve 280. In the
preferred embodiment, valve body 284 will be made from A519-4140 in
grade P110. It will be appreciated that other satisfactory
materials exist and can be used to construct the valve body. The
inclusion of ball keeper pin 288 in ball check valve 280 allows
ball 292 to be changed if necessary, thus prolonging the life of
ball check valve 280. In other embodiments, ball check valve 280
may be a Mingo Manufacturing ball check valve, or other
commercially available ball check valve. Ball check valve 280 is
coupled to one end of screen 272 of lower assembly 232 through
standard coupling means, such as threading. The other end of screen
272 is coupled to inner coupling location 296 of 3-way adapter 276
of lower assembly 232. As disclosed above, washpipe pup or other
conduit may be coupled to either or both of screen-facing 300 and
non-screen-facing 304 outer coupling locations of 3-way adapter
276. In a preferred embodiment, the washpipe pup is coupled to
screen-facing outer coupling location of both upper 228 and lower
232 assemblies, creating an enclosed chamber 308 between lower 232
and upper 228 assemblies.
[0091] In one embodiment of the DPDT, the capturing zone is
determined by the length of workstring between the two-piece
system. For well conditioning with screen gauges customized to suit
wellbore fluids, reverse circulation allows fluid to pass through
the lower ball check and screen system and enter the capturing
zone. The upper assembly, which utilizes a floating ball check
valve that is closed by default, allows clean fluid to pass but not
the debris or particulates the screens have been gauged for.
Forward circulation pushes the floating upper ball check off seat
and allows debris to enter the capturing zone, but eliminates the
contamination of the wellbore from surface debris entering the well
and causing unwanted downhole plugging as the lower ball-check
seats and forces fluid to pass through the lower screen. This
enhances thru-tubing work, acidizing, or other interventions where
delicate equipment has already been installed.
[0092] In one embodiment, the DPDT is ideal for installation at
surface or just below the rotary based on its simple ball check
design, ability for bi-direction flow, and elimination typical
footprints from deck mounted debris filtering equipment. Screens
may be custom built and may be designed for large pit debris,
filtering mud or brine, or capturing cuttings from within the
wellbore. In some embodiments, where the DPDT is designed for
65/8'' drillpipe, the system can accommodate smaller strings with
simple crossovers that may be installed prior to mobilization to
eliminate the need for additional handling equipment on location.
In other embodiments, the DPDT may be designed for drillpipe of
sizes other than 65/8'' drillpipe.
[0093] In some embodiments, the DPDT is ideal for installation on
the deck of an offshore drilling location. Such a deck-mountable
embodiment provides easier access to equipment for maintenance and
monitoring. Additionally, pressure differentials may be observed
throughout the unit to provide immediate indication of plugging or
the buildup of material captured. In some deck-mountable
embodiments, the DPDT may be reconfigured to fit within a deck
crate having predetermined dimensions. The DPDT can be run in a
variety of configurations, allowing it to be contained within
nearly any dimension of deck crate. Referring now to FIGS. 6B-6H,
several views of one deck-mountable embodiment of the DPDT are
shown. In some embodiments, deck-mountable DPDT 2100 may be
comprised of substantially the same components as described above
in regards to FIG. 6A. Other embodiments of the DPDT may practice
the present invention with different or less components than those
shown in FIG. 6A.
[0094] Referring now to FIG. 6D, Deck-mountable DPDT 2100 is
comprised of upper assembly 2104 and lower assembly 2108. In some
embodiments, upper assembly 2104 and lower assembly 2108 may be
secured to deck crate 2110 by securing means 2114. Securing means
2114 can be u-bolts or other suitable means for securing upper
assembly 2104 and lower assembly 2108 to deck crate 2110. In this
embodiment, upper assembly 2104 is comprised of screen 2112, ball
check valve 2116, and 3-way adapter 2120. In a preferred
embodiment, screen 2112 is a thru-tubing screen that is of an
appropriate size, diameter, tensile, burst, collapse, and gauge to
be placed within washpipe pup, tubing, drillpipe, casing, or other
suitable conduit, such as the DeltaPore HP.TM., manufactured by
Delta Screens, or any other conduit. Similar to embodiments of the
DPDT described with respect to FIG. 6A above, 3-way adapter 2120
contains three coupling locations (not shown in FIG. 6D): an inner
coupling location, a screen-facing outer coupling location, and a
non-screen-facing outer coupling location. In some embodiments of
the present invention, the coupling means will be a Hydrill 511
box/pin coupling, API 8RD box/pin GTM 69, or as required for
operational conditions. It will be appreciated by those skilled in
the art that other embodiments will use other coupling means. Inner
coupling location of 3-way adaptor 2120 is coupled to the end of
screen 2112 that is not coupled to ball check valve 2116. 3-way
adapter 2120 also provides a means to couple a washpipe pup or
other conduit to either or both of screen-facing and non-screen
facing outer couplings. In a preferred embodiment, 3-way adapter
2120 is constructed of fairly hard material with some corrosion
resistance which is readily machineable, such as A519-4140 in grade
P110. It will be appreciated that other satisfactory materials
exist and can be used to construct 3-way adapter 2120. In a
preferred embodiment, ball check valve 2116 may be comprised of
ball 2124 which is of very hard and corrosion resistant material,
valve body 2128, and ball keeper pin 2132.
[0095] In a preferred embodiment, lower assembly 2108 is comprised
of screen 2136, 3-way adapter 2140, and ball check valve 2144. In
the preferred embodiment, valve body 2148 will be made from
A519-4140 in grade P110. It will be appreciated that other
satisfactory materials exist and can be used to construct the valve
body. The inclusion of ball keeper pin 2152 in ball check valve
2144 allows ball 2156 to be changed if necessary, thus prolonging
the life of ball check valve 2144. In other embodiments, ball check
valve 2144 may be a Mingo Manufacturing ball check valve, or other
commercially available ball check valve. Ball check valve 2144 is
coupled to one end of screen 2136 of lower assembly 2108 through
standard coupling means, such as threading. The other end of screen
2136 is coupled to inner coupling location (not shown) of 3-way
adapter 2140 of lower assembly 2108. As disclosed above, a washpipe
pup or other conduit may be coupled to either or both of
screen-facing and non-screen-facing outer coupling locations (not
shown) of 3-way adapter 2140.
[0096] In some embodiments, a washpipe pup is coupled to
screen-facing outer coupling location of both upper 2104 and lower
2108 assemblies, creating an enclosed chamber between lower 2104
and upper 2108 assemblies. In other embodiments of deck-mountable
DPDT 2100, such as the embodiment shown in FIGS. 6B-6H, upper/lower
assembly bridge 2160 connects upper 2104 and lower 2108 assemblies,
creating an enclosed chamber between lower 2104 and upper 2108
assemblies. Upper/lower assembly bridge 2160 may be further
comprised of crossover subs 2164, bridge subs 2168, and drain plugs
2172. Crossover subs 2164 may be used to couple the washpipe pups
or other conduits of lower 2104 and upper 2108 assemblies to bridge
subs 2168. Bridge subs 2168 may be coupled together to establish an
enclosed chamber between lower 2104 and upper 2108 assemblies. In a
preferred embodiment, bridge subs 2168 may be constructed of high
pressure iron such as 3 inch 1502 weld iron. It will be appreciated
that other satisfactory materials exist and can be used to
construct bridge subs 2168. In some embodiments, drain plugs 2172
may be removed to allow for removal of debris or washing of the
deck-mountable DPDT without complete disassembly.
[0097] It will be appreciated by those skilled in the art that the
above description of various aspects of various embodiments of the
WPDT may be applied to the various embodiments of the DPDT, and
that various aspects of various embodiments of the DPDT may be
applied to the various embodiments of the WPDT.
[0098] C. Marine Riser Reversing Tool
[0099] The Marine Riser Reversing Tool (MRRT) aspect of the present
invention may be used in systems and methods for cleaning the
internal surface of riser pipes used for drilling, interventions,
and completion/workovers of offshore wells. The MRRT overcomes
issues presently found in existing cleaning systems and methods
including reliance on booster pumps, large annular cross-sectional
areas for carrying fluid and debris out of the well, chemical
contact times, riser margin limitations, and underbalance
management. The MRRT permits reverse circulation of the riser at
reduced pump rates without compromising debris carrying capacity.
The lower pump rate in turn permits longer contact time between
chemicals and the riser wall. Formulations of the chemicals may be
adjusted to capitalize on the slower pump rates and the ability to
allow chemicals to do more work before returning to the
surface.
[0100] The MRRT may work in conjunction with existing tools in
closed and open systems. In a closed system, concerns of pumping
debris beyond the point of entry into a drill pipe are minimized
based on the depth of the point of entry into the drill pipe and
the top of the installed isolation. An open ended point of entry
into the drill pipe (mule shoe, bull nose, etc.) may be used to
clean the top of the tree hardware (caps, crown plugs, etc.). In an
open system, several debris-catching technologies may be utilized,
including a junk basket, a non-ported MRRT, or a tool similar to
the Well Patroller. A port of entry would lie above these tools.
Utilizing the MRRT causes different fluid velocities and pressures
at different locations in the workstring. However, use of the MRRT
should not cause any unwanted pressure increases at the surface of
the well. Regardless, monitoring the drill pipe pressure provides
an indication of any plugging from the MRRT or additional tools
utilized.
[0101] It will be appreciated by one skilled in the art that use of
a preferred embodiment of the present invention incorporating the
MRRT will be particularly beneficial in an offshore drilling
environment where drilling fluids have a tendency to congeal within
the riser pipe. However, other embodiments of the MRRT will provide
a benefit in any environment where riser, casing, tubing, blow out
preventers, trees, and well heads need to be cleaned out. Other
embodiments of the MRRT will be beneficial in aiding sand washing,
cementing, crown plug cleaning, BOP functioning and cleaning, open
water displacements, downhole interval cleaning, whole
conditioning, sand control service tool design, and coiled tubing
applications.
[0102] The MRRT may be used at various depths in a well operation.
The MRRT may be placed at various depths in the borehole based on
well configuration, inserted equipment depth, and/or riser
characteristic limitations. The MRRT may be run below the tree at
various well depths to conduct additional cleaning operations. In
addition, reciprocation and rotation of a workstring equipped with
the MRRT is contemplated. Specifically, the workstring may travel
uphole, travel downhole, and rotate while the MRRT remains
stationary.
[0103] Referring now to FIG. 7, in a preferred embodiment of the
present invention, MRRT 29 is comprised of a cylindrical tool
placed within a sealing element 99, creating two workstring/riser
annuli 100, one above and one below the sealing element 99. In a
preferred embodiment, the body of MRRT 29 is comprised of mandrel
115. Two channels run lengthwise through MRRT 29. These channels
will be referred to as downward channel 117 and upward channel 118.
Each channel receives flow from the workstring and outputs the flow
into the workstring/riser annulus. Downward channel 117 receives
fluid or other material from upper tubing string 101, and outputs
that fluid or other material into workstring/riser annulus 100
below sealing element 99. Upward channel 118 receives fluid or
other material from lower tubing string 102, and outputs that fluid
or other material into workstring/riser annulus 100 above sealing
element 99. Since the fluid returns to the annulus 100 above the
sealing element 99, the velocity of the fluid decreases because the
annulus 100 has a larger cross sectional area than interior of the
workstring. Junk baskets may be employed in the annulus 100 above
the sealing element 99 to capture any debris that is not carried to
the surface due to the reduced velocity. The junk baskets would be
such that the annular space 100 would be minimized to permit
maintenance of velocities comparable to those inside of the
workstring. A pin by box connection, as is commonly used in the oil
and gas industry, may be used to selectively interconnect the MRRT
29 to a workstring.
[0104] In a one embodiment of the present invention, sealing
element 99 comprises cup elements that seal MRRT 29 to the riser's
5 internal diameter and separates the annulus above the MRRT 29
from the annulus below the MRRT 29. Sealing element 99 is further
comprised of spacer ring 112, retaining nut 113, packer sleeve 114,
and packer stop 116. Packer sleeve 114 is a cylinder to which
packing cups are affixed. Packing cups may be visually inspected
for complete bonding, and a pry test may be performed to ensure
full adhesion. Spacer ring 112 fills the void between the two
packing cups that are affixed to packer sleeve 114. Packer sleeve
114 then slides on top of mandrel 115 and is held in place by
packer stop 116 on the top side and retaining nut 113 on the bottom
side. In another embodiment of the present invention an inflatable
element package with a control line run to surface to control
inflating/deflating of the element is also located in the same
place as cup elements.
[0105] In one embodiment of the present invention, MRRT 29 is
positioned in the well above the zone that needs to be cleaned.
FIGS. 8A and 8B depict the MRRT positioned in the riser 5, however
the MRRT can be placed in tubing or casing as well in some
embodiments. MRRT 29 is placed in workstring 98 along with its
sealing element 99, creating a workstring/riser annulus 100 above
and below MRRT 29. Additionally, placement of MRRT 29 creates an
upper tubing string 101 and a lower tubing string 102. Some
embodiments of the MRRT 29 are simple such that the MRRT 29 could
be run without the need for an expert on location and with parts
capable of replacement on location without specialty tools. Various
embodiments of the MRRT 29 may be compatible with existing well
bore clean out technology and may contain a means to be quickly
removed in the event of well control events. In view of the
compatibility, the connection between the MRRT 29 at the
drillstring at large may be a common 75/8'' API REG Box X Pin. The
use of a large and common API connection gives the ability to
crossover to the other possible sizes and connections of
workstrings, tubing, washpipe, etc. without the need for additional
mandrel inventory. This standardization, for example, the lack of
premium threads, also affects production costs.
[0106] MRRT 29 is part of a circulation system that flows from tank
8 through suction line 104 to pump 105. Pump 105 moves cleaning
fluid through pump line 13 to the upper tubing string 101 above
sealing element 99. The cleaning fluid travels down the upper
tubing string 101 to MRRT 29. Once the cleaning fluid reaches MRRT
29, the flow crossover function of MRRT 29 diverts the cleaning
fluid from upper tubing string 101 to workstring/riser annulus 100
below sealing element 99. The cleaning fluid then makes direct
contact with the riser zone that is intended to be cleaned.
Cleaning fluid and coagulated fluid and debris that is cleaned off
the riser continues to travel down the lower workstring/riser
annulus 99 to the bottom of the well. The fluid reenters lower
tubing string 102 and travels up lower tubing string 102 to MRRT
29, where flow is again diverted, causing the fluid to enter the
workstring/riser annulus 100 above sealing element 99. Fluid
continues to travel up upper workstring/riser annulus 100 to flow
line 9 and then back to tank 8 in the surface circulating
system.
[0107] It will be appreciated that because the cleaning fluid and
coagulated fluid and debris that are cleaned off riser 5 travels up
the lower tubing string 102, much lower pressure and consequently
annular velocity is required to bring the fluid and debris to the
surface. In some embodiments, the magnitude of increased efficiency
may be on the order of tenfold based on riser and workstring
diameters. Such a reduction in required annular velocity provides
several advantages. Higher annular velocities associated with
traditional cleaning systems and methods increase the risks
associated with mechanical failure of associated equipment and
decrease efficiency of surface operations such as filtering.
Further, use of MRRT 29 allows an operator to achieve operating
pressures necessary for proper clean-up irrespective of seabed
depth. Other advantages of using MRRT 29 for cleaning operations
include: aiding in debris removal by allowing blow out preventers
to be functioned while cleaning; cleaning above tree plugs and run
an impression block downhole before running subsea test trees; and
aiding in greener open water riser clean-ups.
[0108] Now referring to FIG. 9, additional views of the MRRT are
provided. FIG. 9 is a cross-sectional view of the MRRT taken along
a longitudinal plane of the MRRT. As described above, the body 120
of the MRRT has two ports that redirect the flow of fluid in a
borehole. The large entrances and exits of these ports permit
debris of nearly any size to pass through the MRRT. In addition,
the generally tapering shape of the MRRT minimizes erosion of the
MRRT. The ports are also sufficiently spaced apart from each other
to minimize the effects of erosion between the ports. In other
words, the material between the two ports is adequate to provide
durability and extend the life of the MRRT over many cycles of use.
Lastly, the ports are substantially oriented about a longitudinal
axis and comprise no substantial bends, again, to minimize the
effects of any erosion.
[0109] The embodiment of the MRRT in FIG. 9 comprises a retaining
nut 124, a set screw 128, an o-ring 132, two cup seals 136, and a
spacer sleeve 140. The set screw 128 may be coated with Blue
Loctite and torqued to 35 ft-lbs to prevent the set screw 128 from
backing downhole. The cup seals 136 are nitrile in a preferred
embodiment. The cup seals 136, a cup retainer 138, the o-rings 132,
and a cup sleeve are held in place on the body 120 of the MRRT by
the spacer sleeve 140 and a retaining nut 124 with a set of backup
screws.
[0110] The cup seal 136 has several design aspects and benefits.
The MRRT has the ability to receive cup seals 136 of various sizes
to accommodate multiple riser diameters without the requirement of
a new body 120 design. In another embodiment, the MRRT comprises
cup seals 136 of varying diameter. Thus, one cup seal 136 may
accommodate a smaller diameter, and another cup seal 136 may
accommodate a larger diameter. Embodiments of the MRRT and cup
seals 136 may accommodate a differential pressure rating, for
example, a minimum of 1,000 psi in excess of typical riser margins.
Further, cup seals 136 are easily replaceable, self-setting, and
self-sealing in various embodiments of the invention.
[0111] While a cup seal 136 is shown in FIG. 9, other seals such as
an inflatable seal may be used. In some embodiments, a cup seal
with an inner diameter of 2.times.2.5'' and an outer diameter of
18.5'' may accommodate a riser size of 19.5''. Similarly, an
inflatable seal may have an inner diameter of 2.times.2.5'' and an
outer diameter of 18.5'' to accommodate a riser size of 19.5''. Cup
seals and inflatable seals may be de-rated to expected pressures,
which would allow the seals to leak at specified pressures to
eliminate a riser burst scenario.
[0112] The MRRT inflatable-type packer sleeve may provide, inter
alia, (a) a differential pressure rating of, for example, a minimum
1,000 psi in excess of typical riser margins; (b) a reusable rubber
element for entry through restrictions; (c) an alternative for
users not comfortable with the reliability of the cup seal assembly
design; and (d) a gateway into deeper downhole applications.
[0113] The cup seal 136 and/or the overall cup assembly may
comprise a taper to aid in entering a casing or tubing. Further,
the taper of the cup seal 136 helps the MRRT negotiate
abnormalities in the well and prevent the cup seal 136 from
overengaging slip joints. In addition, a riser brush may keep the
MRRT centered in the casing or tubing, and a 18.75'' bow spring
centralizer may also be used to keep the MRRT centered in the
casing or tubing.
[0114] Various components of the MRRT shown in FIG. 9 may have
dimensional aspects. The cup seal length 144 may be approximately
8.5''. However, in various embodiments the cup seal length 144 may
be between approximately 4.0 and 18''. The overall length of the
cup assembly 148 may be approximately 21.75''. It will be
appreciated that in various embodiments, the overall length of the
cup assembly 148 may be between approximately 12 to 36''. Lastly,
the overall length of the entire MRRT 152 may be approximately
60''. However, in various embodiments, the overall length 152 may
be between approximately 24 and 120''.
[0115] The MRRT may have a male end 156 and a female end 172 based
on those typically used in deep-water workstring applications with
the ability to recut or crossover. For example, the male end 156
may be a 75/8'' API REG Pin. The male end 156 may have a first
diameter 160 that is approximately 8.63'', a second diameter 164
that is approximately 31.5'', and third diameter 168 that is
approximately 19.5''. Conversely, the female end 172 may be a
7.5/8'' API REG Box. The female end 172 may have a first diameter
176 that is approximately 8.63'', a second diameter 180 that is
approximately 12.25'', and a third diameter 184 that is
approximately 16.5''. While these dimensions are based on an API
Specification, it will be appreciated that the MRRT may accommodate
other API standards or any other standards.
[0116] The various dimensions of the male end 156 and the female
end 172 may be used to define a conduit cross sectional area and an
annular cross sectional area. For example, the first diameters 160,
176 may define a conduit cross sectional area that is circular in
shape and that ranges between the male end 156 and the female end
172. The conduit cross sectional area substantially corresponds to
the conduit formed by a drillstring or drill pipe. Similarly, the
second diameter 164 defines an outermost boundary of an annular
cross sectional area while the first diameter 160, 176 define an
innermost boundary of the annular cross sectional area. The annular
cross sectional area also ranges between the male end 156 and the
female end 172. The annular cross sectional area substantially
corresponds to the annular spaced formed between the outer surface
of a drillstring or drill pipe and the inner surface of a casing, a
tubing, a riser, etc.
[0117] The design of the MRRT shown in FIG. 9 accommodates various
design parameters and specifications. The MRRT body 120 may be
resilient yet machineable 4140 alloy steel to help give the MRRT an
exceptionally long operational life. The flow reduction areas of
the body 120 may be designed with a 30 degree incident angle to
help reduce perceived erosion at the reduction. Also, the ports may
be designed with a diameter of 2.5'' to help balance the reduction
of velocities within the ports with wall thicknesses great enough
to handle years of erosional wear.
[0118] Erosion calculations may be performed on the reduction areas
as well as the ports to determine the approximate life of the body
of the MRRT. In various embodiments, the assumptions made for
erosion calculations may comprise: (a) brine fluid with a density
of 1350 kg/m3 (11.27 lbs./gal) at 77.degree. Fahrenheit, (b) 25
BBL/Min flow rate, (c) a sand content of 2% by unit volume, (d) a
large sand grain size (250 microns), and (e) 3,000 psi differential
pressure rating. Based on these assumptions and calculations, the
MRRT tool should be capable of service for greater than 2 years of
continuous flow. This would equate to greater than 26 million
barrels of flow through each port prior to erosional communication
within the tool. Assuming a flow volume of 6,000 barrels (4 hours
at 25 BBL/Min) per clean out cycle; this would equate to over 4,000
cycles for the life of the tool.
[0119] While some preferred embodiments will utilize the above
disclosed dimensions, it will be appreciated by those skilled in
the art that other dimensions and specifications may be applied and
utilized without departing from the scope of the invention is not
limited to such dimensions and specifications.
[0120] Below is a table showing the characteristics of the
components of an MRRT according to come embodiments of the present
invention
TABLE-US-00001 Collapse Burst Tensile Makeup Max Min ID Weight
Rating Rating Rating Torque Item Material OD in in lbs psi psi kips
ft-lbs Body A-519 16.520 2.500 1,453 36,820 55,215 2,288 66,285
4140 Grade 110 Retaining 1018 Cold 13.510 12.070 22.77 N/A N/A N/A
200 Nut Roll Steel Set Alloy 0.500 N/A 0.06 N/A N/A N/A 35 Screw
Steel Q&T O-ring Nitrile 12.375 12.000 0.05 N/A N/A N/A N/A
Rubber 70 Durometer Cup Seal 1018 Cold 13.510 12.340 55.33 N/A N/A
N/A N/A Sleeve Roll Steel Cup Seal 1018 Cold 17.270 13.535 37.95
N/A N/A N/A N/A Retainer Roll Steel Cup Seal Nitrile 18.520 13.500
32.08 N/A N/A N/A N/A Rubber Rubber 70 Durometer Spacer 1018 Cold
13.510 12.300 6.48 N/A N/A N/A N/A Sleeve Roll Steel QTY REQ Item #
Per MRRT Description Part Number 1 1 ea MRRT Body, 12.250'' OD with
SS-MRRT-1225- 75/8'' API REG Box X Pin BODY Connections 2 1 ea
Retaining Nut SS-MRRT-1350- RETN 3 6 ea Set Screw, 1/2''-13UNC C
3/4'' LG SS-MRRT-0500- Cup Point Alloy Steel Cadmium STSS Platted 4
4 ea O-ring, Nitrile 70 Durometer Size SS-MRRT-1237- 2-381 ORNG 5 2
ea Cup Seal Assembly 19.50'' OD SS-MRRT-1950- CSAS 6 1 ea Space
Sleeve SS-MRRT-1350- CPSL
[0121] Various methods may be utilized to manufacture the MRRT of
the present invention. In some embodiments, gundrilled ports are
advantageous to avoid using multiple components for the MRRT body
120. Using this method, the stock material may be larger than the
final dimensions of the MRRT to allow for proper entrance and exit
points for the gundrilling process. Four holes may be gundrilled
into the stock material. Specifically, two holes correspond to two
entrance ports, and two holes correspond to two exit ports.
Precision is key as the entrance and exit hole for a given port
will meet at the center of the stock material. Using multiple holes
in this method stabilizes the gundrilled shaft and results in more
accurately and precisely drilled ports, which is imperative in
achieving quality flow paths. Custom jigs may be used to manipulate
the entry points on the stock material to achieve the required exit
angles. After the four holes are drilled, the stock material is
turned down into the body profile.
[0122] In one specific embodiment of the present invention, the
manufacturing process for the body 120 and the ports of the MRRT is
as follows. (a) the stock material is placed into a horizontal
boring mill and two 2.50'' internal holes are drilled at a
specified angle halfway through the body 120; (b) the stock
material is then rotated 180 degrees end over end, and the internal
holes are drilled from the other end meeting halfway for completion
of holes through the body 120; (c) the material is inspected for
accuracy of drilled holes for verification they meet precisely at
the vertex of the two holes; (d) the outer diameter profile of the
body 120 is then machined completely from both ends on a machine
lathe; (e) 75/8'' API REG Box and Pin connections are machined at
the two ends of the body 120 per API Specification 7-2, e.g.,
Eighth Edition, Jul. 1, 2015; (f) the completed body 120 is
inspected for verification of all dimensional tolerances. Between
steps (d) and (e), a hardening may be performed to ensure a more
consistent through hardening of the tool. In some embodiments, the
hardening may be to 100 ksi.
[0123] The retaining nut, spacer sleeve, and sleeves required for
the cup seal assembly are manufactured in an exemplary embodiment
of the present invention as follows: (a) stock material is utilized
and each item is machined completely on a machine lathe; (b) the
machined items are inspected for verification of all dimensional
tolerances.
[0124] The cup seal assembly may also be manufactured according to
a specific process in some embodiments of the present invention.
For example, a cup seal may be manufactured as follows: (a) the
machined steel sleeves required for the cup seal assembly are
placed into a pre-made compression tooling mold; (b) the rubber
material is loaded and is molded and bonded to the steel sleeves
utilizing a proprietary process; (c) the completed assembly is
removed from the mold and inspected for all dimensional
tolerances.
[0125] Once all of the components of the MRRT are manufactured, the
components may be assembled into a complete MRRT. In some
embodiments, the MRRT may be designed to have as few parts as
possible and has no moving parts. The MRRT may be assembled per
approved procedures which simply comprise sliding the cup seal
assembly sleeves, spacer sleeve and retaining nut onto the body and
tightening per recommended makeup torque. Six additional socket set
screws built into the retaining nut may serve as a backup device to
prevent it from backing off. Because of the weight of the MRRT
body, specially designed cradle fixtures may be required to support
the tool in order to ease assembly. These same fixtures may ship
with each tool for shipping and maintenance/assembly purposes on
location. The MRRT may come equipped with both box and pin lift
subs. For standard assembly, the MRRT may be placed standing
upright with the box end down and with the thread protector
installed. This may be accomplished by lifting the MRRT out of its
cradle using the pin side lifting sub and setting the box end down
into the accompanying fixture. The cup seal assembly components can
then be assembled as described above.
[0126] Once manufactured, assembled, and installed, the MRRT may
require maintenance. Achieving the goal of minimal pieces for the
MRRT will keep maintenance efforts and costs to a minimum. The
simple design should stand up to the harsh offshore environment and
the neglect of users. However, the cup seal assembly is the one
piece that may not withstand repeated abuse as it is responsible
for maintaining a pressure differential. This item is thus a
tangible part to be replaced once it begins to show wear or cuts in
the rubber. Maintaining the body, retaining nut, and spacer sleeve
may fall under a standard maintenance protocol with respect to
threads, magnetic particle inspection (MPI), and general washing.
Inspection of the remaining wall thickness will also be required to
ensure that an appropriate amount of material remains between the
entry and exit flow paths of the body.
[0127] A maintenance schedule may be implemented to preserve and
protect the MRRT. Generally, the MRRT's design requires little
maintenance. The maintenance will be accomplished through an
approved procedure and will consist of recommendations for both
pre-job and post-job as well as storage and shelf life. The body
connections may require a UV (black light) non-destructive testing
(NDT) before each job. The entire body may require periodic UV NDT
for any signs of substantial erosion of the body. The body should
be cleaned and coated with a rust preventing agent after each use
to prevent excessive moisture exposure.
[0128] The cup seal assemblies are manufactured from durable rubber
and hold pressure downhole. The cup seal assembly elements are in
constant contact with the inner diameter (ID) of the riser when
being run downhole as well as when pressure is applied; therefore
the cup seal assemblies, including o-rings, are replaced once any
wear or cuts are noticed in the cup seals. Each cup seal assembly
may be able to complete multiple trips down the riser depending on
the roughness of the riser and depth of travel of the tool.
[0129] All of the MRRT's components are expected to have a long
shelf life when maintained properly. All components will require
periodic checks for both wear and erosion. The MRRT may be shipped
in a specially designed cradle fixture. The MRRT can be shipped
fully assembled or in pieces if the operator chooses to assemble
the MRRT on location. It is highly recommended that the MRRT be
fully assembled before reaching location except for times when
circumstances do not allow.
[0130] Now referring to FIG. 10, an alternative embodiment of the
MRRT 29 is provided where a return adapter 188 extends upward from
the MRRT 29. The return adapter 188 has a first inner tube 192 and
a second inner tube 196. The first inner tube 192 operably
interconnects a surface pump 200 to the downward channel 117 of the
MRRT 29, and the second inner tube 196 operably interconnects the
upward channel 118 of the MRRT 29 to a surface return 204. In some
embodiments, the second inner tube 196 has a diameter that is
substantially similar to the diameter of the upward channel 118 and
or the interior of the workstring below the MRRT 29. This allows
the fluid traveling through the upward channel 118 to maintain a
relatively higher velocity to the surface of the well.
[0131] The two inner tubes 192, 196 are mounted in the return
adapter 188 at an elevator catch 208 at an uphole end of the return
adapter 188 and at a block 212 at a downhole end of the return
adapter 188. Seal stabs 216 may be positioned on the downhole side
of the return adapter 188, and the seal stabs 216 may be
selectively interconnected to the block 212. Next, a quick make up
connection 220 may be utilized to selectively interconnect the seal
stabs 216 into a polished bore receptacle (PBR) 224 positioned on
the uphole side of the MRRT 29.
[0132] D. Bi-directional Chamber Trap
[0133] The Bi-directional Chamber Trap (BDCT) aspect of the present
invention may be used in systems and methods for drilling and
completion of wells. It will be appreciated by one skilled in the
art that use of the BDCT will be beneficial in any environment
where fluid entering or leaving the well needs to be filtered. One
benefit of the BDCT is that it permits debris and trash upstream of
the mud pump to be captured before entering the drill pipe via the
top drive.
[0134] In a preferred embodiment of the present invention, BDCT 26
serves as a bi-directional filter that allows a single in-line tool
to provide fluid filtration in either flow direction. The BDCT
provides the additional benefit of being capable of running in
parallel (as shown in FIG. 12B) or in series with additional BDCTs
to provide redundancy or additional effectiveness. Redundancy
allows for operations to continue if less than all units experience
a failure. Additional effectiveness is achieved at least through
the addition of additional chamber space to hold filtered debris or
through the use of differing filter screen gauges to filter smaller
debris. It will be appreciated that use of some embodiments of the
BDCT will provide a last defense against debris or other
undesirable particulate from being pumped into the well or being
pumped out of the well and into the pumping system.
[0135] Referring to FIG. 11, in a preferred embodiment of the BDCT,
BDCT 26 is comprised of a horizontal cylindrical chamber 108 with
three ports. In this embodiment, one port is located on each end of
the cylindrical chamber. In a preferred embodiment, the ports are
offset from one another both horizontally and vertically, with
upstream port 109 being located closer to the top of BDCT 26 than
downstream port 110. It will be appreciated that the placement of
upstream port 109 closer to the top of chamber 108 creates a larger
area in the bottom of chamber 108 to allow debris 31 to settle and
collect when BDCT 26 is operated in the forward direction. BDCT 26
being placed in-line in a circulation system, it will be
appreciated that the port into which fluid flows during normal
operation of the circulation system is upstream port 109, whereas
the port on the other side is downstream port 110. The third port
is a clean-out port 111 and is located at the bottom of chamber
108, with clean-out valve 39 coupled to clean-out port 111 on the
exterior of BDCT 26. On the interior of the chamber, coupled to
upstream port 109 is upstream filter medium 26.1 and coupled to
downstream port 110 is downstream filter medium 26.4. Both filter
mediums can be the DeltaPore HP.TM., manufactured by Delta Screens,
although other mediums well known in the art can be used. Coupled
to the end of upstream filter medium 26.1 is upstream ball check
valve 26.2. Coupled to the end of downstream filter medium 26.4 is
downstream ball check valve 26.5. In a preferred embodiment, the
ball check valves 26.2, 26.5 may be comprised of ball 93 of very
hard and corrosion resistant material, valve body 94, and ball
keeper pin 95. The inclusion of ball keeper pin 95 in ball check
valves 26.2, 26.5 allows ball 93 to be changed if necessary, thus
prolonging the life of the ball check valves 26.2, 26.5. In some
embodiments, ball check valves 26.2, 26.5 may be a Pedcor series
13-3000 ball check valves, although other commercially available
ball check valves may be used. Further included inside the chamber
108 is baffle 26.3, positioned in a manner that diverts the flow of
fluid and debris 31 inside chamber 108 to allow gravitational force
greater time to aid in the separation of debris 31 from fluid.
Additionally, in a preferred embodiment of the present invention,
BDCT 26 may include wear plate 26.6 in order to protect against
excessive wear at the point where debris-laden fluid initially
contacts the inside of chamber 108.
[0136] In one embodiment of the invention, the BDCT is placed into
a circulation system of a rig surface system, such as that depicted
in FIGS. 1A and 1B. The circulation system consists of suction pits
17, mud pump 14, standpipe 11, choke manifold 12 and BDCT 26, which
together work to feed fluid to the well. In this embodiment, BDCT
26 is placed downstream of mud pumps 14 and upstream of stand pipe
11. The forward circulation path of the circulation system travels
from mud pump 14 through BDCT 26 to standpipe 11.
[0137] In one embodiment of the invention, fluid potentially
carrying debris and/or trash is pumped by mud pump 14 to BDCT 26.
The pumped fluid enters BDCT 26 through upstream port 109. Any
debris or trash in the fluid passes through upstream ball check
valve 26.2 and enters chamber 108 of BDCT 26. Once the fluid and
debris 31 or trash enters chamber 108, the flow path is diverted by
baffle 26.3. The diversion of the flow path facilitates the
separation of the debris 31 and trash from the fluid. As debris 31
separates from the fluid, it settles in the bottom of chamber 108.
As fluid continues to flow along the flow path through BDCT 26 it
arrives at downstream filter medium 26.4. Because downstream ball
check valve 26.5 is closed while the circulation system pumps in
the forward direction, debris 31 and trash become trapped in
chamber 108. The fluid, removed of any debris 31, leaves BDCT 26
through downstream filter medium 26.4 and moves to standpipe 11
towards the well.
[0138] Referring to FIG. 12A, in some embodiments of the present
invention, an alert system provides a means to alert a well
operator that BDCT 26 has filled or contains significantly large
debris 31 or trash. The alert system is comprised of upstream
pressure gauge 42 and downstream pressure gauge 61, which are
located upstream and downstream, respectively, of forward direction
flow into BDCT 26. Pressure gauges 42 and 61 monitor the pressure
differential across BDCT 26 and indicate a blockage when a pressure
trend is observed. Typically, this trend will very sharp, but
different embodiments will indicate blockage in different manners.
In some embodiments, in-line pop-offs 49 and 54 activate when a
predetermined pressure is registered, which direct flow to pop-off
bleed lines 50 and 55, which in turn feed into clean out line 52.
In single BDCT embodiments, a bypass valve system, consisting of at
least bypass valve 35 and bypass pipe 36, redirects fluid past BDCT
26 so that operations are not interrupted when BDCT 26 is not
operational for any reason. Activation of the bypass valve system
or parallel manifold valve system may occur via manual operation or
automated limits.
[0139] Referring to FIG. 12B, in another embodiment of the present
invention, two or more BDCTs 26 are run in parallel. In this
embodiment, the flow of pumped fluid travels through a main valve
65 into a parallel manifold 66 that is coupled to both BDCTs 26.
Each branch of the parallel manifold 66 contains valves 34 capable
of stopping flow to one of BDCTs 26. In parallel BDCT embodiments,
the parallel manifold valve system can divert fluid to the parallel
BDCT in the event a BDCT is not operational or the alert system
described senses a blockage. It will be appreciated that such a
system will provide added benefit to a single BDCT system because
at least one BDCT will usually be in operation. It will further be
appreciated that in either single or parallel BDCT embodiments,
operators can continue to operate the well when a BDCT is plugged
with large debris.
[0140] In another embodiment of the preferred invention, the flow
path of the circulation system is reversed. When fluid is pumped
through BDCT 26 in the reverse direction, upstream ball check valve
26.2 closes and downstream ball check valve 26.5 opens. This
configuration allows debris to enter BDCT 26 through downstream
port 110 and become trapped in chamber 108. Fluid leaves BDCT 26
through upstream filter media 26.1, while debris is trapped by
closed upstream ball check valve 26.2.
[0141] In the event BDCT 26 becomes plugged or needs periodic
cleaning, BDCT 26 may be flushed by closing downstream valve 57 and
opening clean-out valve 39. Clean-out valve 39 may be plumbed to a
cuttings box, trash pit, shale shaker, mud tank or other location
where it is desired that the debris be placed.
[0142] In the event BDCT 26 must receive a filter medium 26.1, 26.4
inspection or replacement, flow may be directed in the same manner
as in the event of a debris blockage. That is, a single BDCT
embodiment may be bypassed and a parallel BDCT embodiment may allow
flow to be diverted to the one or more other BDCTs. Once flow is
diverted from BDCT 26, isolation of the unit can be accomplished by
closing upstream valves 34 and 40 to create a double barrier. Quick
Test Unions ("QTU") 38 are then broken to access upstream or
downstream filtering mediums 26.1, 26.4 for replacement or
inspection. Once replaced or inspected, each QTU 38 is capable of
being retested at the connection without retesting the rig
circulation system.
[0143] As noted above, there may be various combinations of the
devices and methods described herein. In one exemplary system, a
MRRT is utilized in conjunction with a WPDT. As such, one
embodiment of the invention may comprise a drilling string having a
reversing tool that changes the downhole flowpath between a tubing
and an annular space, wherein the reversing tool is located at a
first position in the borehole, a debris trap positioned in the
tubing, wherein the debris trap is located at a second position in
the borehole, wherein the second position is deeper in the borehole
than the first position.
[0144] The foregoing description of the preferred embodiments of
the invention is by way of example only, and other variations of
the above-described embodiments and methods are provided by the
present invention. The embodiments described herein have been
presented for purposes of illustration and are not intended to be
exhaustive or limiting. Many variations and modifications are
possible in light of the foregoing teaching.
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