Drilling system and method with annular flushing separation device

Abstract

A drilling system for drilling a wellbore includes a drive mechanism and a separation device disposed upstream of the drive mechanism. The separation device filters at least a portion of any solids from the drilling medium flowing through a filtration flow path of the separation device. The separation device flushes at least a portion of the filtered solids through a flushing flow path, through a flushing outlet on an outer surface of the separation device, and into an annular space between the outer surface of the separation device and the wellbore. Optionally, the drilling system includes a second drive mechanism and a second separation device disposed above the second drive mechanism.

Description

[0001] background

[0002] During the process of drilling and maintaining the wellbore, drilling fluid is pumped through drilling motors (e.g., positive displacement motors) and other drilling and completion equipment (e.g., friction reduction tools, impact hammers, and turbines). Most drilling fluids contain solid particles (e.g., weighted materials such as barite and hematite; low-gravity solids such as bentonite, crushed rocks, and drill cuttings). Certain parts of the drilling and completion equipment are sensitive to solid particles in the drilling fluid. For example, some drilling motors include only metal parts that do not flex when drilling fluids containing solid particles flow between the parts. Instead, solid particles often wedge between two metal parts, which causes the drilling motor to wear out prematurely or stop rotating, causing the metal-to-metal drilling motor to fail. The power section of other drilling motors includes an elastomeric material that flexes to enable solid particles to flow through the drilling motor. However, these elastomeric materials may begin to degrade or fail when the drilling motor is exposed to high temperatures in the wellbore or to oil-based drilling fluids with a low aniline point.

[0003] In both cases, a filter is sometimes located upstream of the drilling motor to reduce the amount of solid particles in the drilling fluid before the drilling fluid enters the drilling motor. However, the filter has a limited capacity for collected solid particles and fills up after a period of time. Once the filter reaches capacity, some conventional filters direct the drilling fluid through a path within the filter to bypass the solid particle capture area of ​​the filter, thereby retaining any solid particles contained therein while allowing unfiltered drilling fluid to reach the downstream drilling motor.

[0004] Figure 1 and Figure 2 An example of a conventional filter 2 is shown. Fluid flowing through the filter 2 is directed to flow over the filter surface 4 so as to collect solid particles within the filter sleeve 6. When a predetermined amount of solid particles are retained within the filter sleeve 6, the associated pressure drop causes the shear pin 8 to break and release the filter sleeve 6, which moves downstream to open the bypass port 10, as shown in FIG. Figure 2 In this position, when the filter sleeve 6 is filled with solid particles, the fluid is allowed to continue to flow through the filter 2. However, the fluid flowing through the bypass port 10 is unfiltered, which increases the possibility of solid particles damaging the downstream drilling motor.

[0005] In order to remove the collected solid particles from the filter, conventional filters are usually pulled out of the drill string for cleaning. Figure 1 and Figure 2The filter 2 in the wellbore is pulled out of the drill string to remove the collected solid particles before the fluid can be filtered again. Removing the filter from the wellbore requires the user to stop the drilling operation and results in wasted drilling time and increased drilling costs. Alternatively, the collected solid particles can be cleared from the filter by opening the solid particle collection area of ​​the filter to flush the collected solid particles downstream through the central fluid path to the drilling motor with the flow of drilling fluid. Flushing the collected solid particles downstream with the drilling fluid causes an increase in the amount of solid particles flowing through the drilling motor, which increases the likelihood that the solid particles will become wedged between two metal components in the metal-to-metal drilling motor, thereby increasing the likelihood that certain drilling motors will wear prematurely or stop working altogether.

[0006] Therefore, conventional filters and metal-to-metal drilling motors are not typically used in applications where the drilling fluid contains solid particles. Instead, these tools are typically used only when the drilling fluid does not contain solids, which is disadvantageous in most drilling applications. In applications involving solid particles in the drilling fluid, drilling motors with elastomeric components are typically used. However, certain elastomeric materials begin to decompose at high temperatures (e.g., temperatures in excess of 320°F), to which drilling tools are exposed in certain areas of underground wellbores (i.e., high temperature areas). In wellbores that pass through high temperature areas, metal-to-metal drills are the only option.

[0007] There is a need for a drilling system that filters solid particles from a drilling fluid and removes the collected solid particles from a filter without removing the system or the filter from the wellbore and without releasing the collected solid particles through a drilling rig. There is also a need for a drilling system that can effectively use the solid particles within the drilling fluid even when the drilling system is exposed to high temperatures. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a cross-sectional view of a prior art filter device in a filtering position.

[0010] Figure 2 It is in bypass position Figure 1 A cross-sectional view of a prior art filter device is shown.

[0011] Figure 3 is a front view of the drilling system of the present disclosure.

[0012] Figure 4 is a schematic diagram of the fluid flow through the separation device of the drilling system in the filtering mode.

[0013] Figure 5 is a schematic diagram of the fluid flow through the separation device of the drilling system in the activated mode.

[0014] Figure 6is a cross-sectional view of one embodiment of a separation device of a drilling system in a filtering mode.

[0015] Figure 7 is in active mode Figure 6 A cross-sectional view of a separation device.

[0016] Figure 8 is a cross-sectional view of an alternative embodiment of a separation device of a drilling system in a filtering mode.

[0017] Fig. 9 is in active mode Figure 8 A cross-sectional view of a separation device.

[0018] Fig.10 is a cross-sectional view of another alternative embodiment of a separation device of a drilling system in a filtering mode.

[0019] Fig.11 is in active mode Fig.10 A cross-sectional view of a separation device.

[0020] Fig.12 is a partial cross-sectional view of an embodiment of a drilling system in which the drive mechanism includes a Moyno motor having a metal stator profile.

[0021] Fig.13 is a partial cross-sectional view of an embodiment of a drilling system in which the drive mechanism includes a Moyno motor having a metal stator profile integrally formed with a stator housing.

[0022] Fig.14 is a partial front view of an embodiment of a drilling system in which the drive mechanism includes a vane motor.

[0023] Fig.15 is from Fig.14 A cross-sectional view taken along line 15-15 in FIG.

[0024] Fig.16 is a partial front view of an embodiment of a drilling system in which the drive mechanism includes a turbine motor.

[0025] Fig.17 is from Fig.16 A cross-sectional view taken along line 17-17 in FIG.

[0026] Fig.18 is a partial cross-sectional view of an embodiment of a drilling system in which the drive mechanism includes a friction reduction tool in an open valve position.

[0027] Fig.19 yes Fig.18 A partial cross-sectional view of an embodiment of a drilling system is shown with the friction reduction tool in a closed valve position.

[0028] Fig. 20 is a partial cross-sectional view of an embodiment of a drilling system in which a drive mechanism includes a hammer device in a first position.

[0029] Fig.21 yes Fig. 20 A partial cross-sectional view of an embodiment of a drilling system is shown with the hammer assembly in a second position.

[0030] Fig. 22 is a schematic diagram of an embodiment of a drilling system positioned in a subterranean wellbore using a coiled tubing string.

[0031] Fig.23 is a schematic diagram of an embodiment of a drilling system including a bending motor positioned in a subterranean wellbore using a tubular drill string.

[0032] Fig.24 is a schematic diagram of an embodiment of a drilling system including a rotationally steerable system positioned in a subterranean wellbore using a tubular drill string.

[0033] Fig.25 is a schematic diagram of an embodiment of a drilling system including two separation devices and two drive mechanisms.

[0034] Fig.26 is a cross-sectional view of an upstream separation device and a downstream separation device in filtration mode.

[0035] Fig. 27 is a cross-sectional view of an upstream separation device and a downstream separation device when the upstream separation device is in a full flushing mode.

[0036] Fig.28 is a cross-sectional view of an upstream separation device in filtration mode and a downstream separation device in flushing mode.

[0037] Fig.29 is a cross-sectional view of an upstream separation device in a partial flushing mode and a downstream separation device in a full flushing mode.

[0038] Detailed Description of Selected Embodiments

[0039] A drilling system is disclosed herein that includes a drive mechanism and a separator that is self-cleaning by flushing collected solids into an annular space surrounding an outer surface of the separator. Neither the drive mechanism nor the separator includes any high temperature sensitive materials.

[0040] Figures 3 to 29 Several embodiments of the drilling system disclosed herein are shown, wherein many other embodiments within the scope of the claims will be apparent to those skilled in the art after reviewing this disclosure.

[0041] refer to Figure 3 , the drilling system 20 includes a separation device 22, which is connected upstream of a drive mechanism 24, which is connected upstream of a drill bit or a milling cutter. The drive mechanism 24 may include any device that converts hydraulic horsepower or pneumatic horsepower into mechanical horsepower (including but not limited to mechanical horsepower for driving a drill bit or a milling cutter, providing power for a generator, activating a valve, activating any actuating device, or generating vibration or impact). For example, the drilling mechanism 24 may include a positive displacement motor (e.g., a vane motor, a Moyno motor), a turbine, a friction reduction tool, an impact motor, a vibration generating tool, and an impact generating tool. The separation device 22 is configured to remove at least a portion of the solid particles contained in the fluid flowing through the separation device 22 before the fluid flowing through the separation device 22 reaches the drive mechanism 24. Non-limiting examples of solid particles that may be contained in the fluid include drill cuttings (e.g., rock particles), weighting materials (e.g., barite), and scale from a pipeline. The separation device 22 is also configured to release the collected solids through a flushing outlet 28 when activated. Optionally, the drilling system 20 may further include a steering mechanism 32 disposed downstream of the driving mechanism 24 .

[0042] In some embodiments, both the separation device 22 and the drive mechanism 24 are elastomer-free, such that all components are configured to operate at temperatures above 320° F. In certain embodiments, the elastomer-free separation device and the drive mechanism are configured to operate at temperatures between 320° F. and 1110° F., or any subrange therein. In some embodiments, all components of the drive mechanism 24 are formed of one or more metallic materials.

[0043] Figure 4 The flow of fluid through the separation device 22 in the filtering mode is shown. The fluid flowing into the separation device 22 is directed to flow from the "dirty side" of the filter to the "clean side" of the filter. The filter medium 34 retains solid particles on the "dirty side" while the fluid flows through the filter medium 34 to the "clean side". In the filtering mode, the clean fluid is directed to the downstream bottom hole assembly ("bottom hole assembly, BHA"), including the drive mechanism 24.

[0044] Figure 5 2 shows the flow of fluid through the separator 22 in the flushing mode. The fluid flowing into the separator 22 is directed to flow from the "clean side" of the filter to the "dirty side" of the filter. The fluid flows through the flushing outlet 28 (at Figure 3 ) flushes some or all of the collected solid particles contained within the separation device 22 into the annular space surrounding the outer surface of the separation device 22.

[0045] refer to Figure 6, the separation device 22 may include a filter 36. The filter 36 includes an outer cavity 38 extending from a fluid inlet 40 to a base 42. The base 42 includes a fluid port 44 and a valve 46, which is configured to open and close the fluid port 44. The fluid port 44 extends from the outer cavity 38 to a flush outlet 28, which opens into an annular space 48 surrounding an outer surface 50 of the filter 36 and within a wellbore or casing 52. The filter 36 also includes a central block 54 extending to a filtering surface 56, which together with the filtering surface 56 forms an inner boundary of the outer cavity 38. The opening in the filtering surface 56 extends from the outer cavity 38 to the central cavity 58, and the central cavity 58 extends from the space within the filtering surface 56 to the fluid outlet 60. Figure 6 The arrows in the figure show the flow path of the fluid through the filter 36 in the filtering mode when the valve 46 is closed. Specifically, the fluid enters the filter 36 through the fluid inlet 40 and flows through the outer cavity 38, through the openings in the filtering surface 56, through the central cavity 58, and through the fluid outlet 60. When the fluid flows through the openings of the filtering surface 56, all or a portion of the solid particles contained in the fluid are retained in the outer cavity 38. Over time, the solid particles accumulate in the outer cavity 38 and begin to fill the outer cavity 38. In some embodiments, the separation device 22 is automatically activated in response to an automatic trigger (e.g., a pressure trigger). As used herein, "automatic activation" is independent of the surface. For example, when a predetermined fluid pressure upstream of the filtering surface 56 increases in response to the filling of the outer cavity 38, the valve 46 opens. In other embodiments, the valve 46 opens in response to a signal received from the wellbore surface. Such a signal can be, but is not limited to, a pressure pulse sequence (mud weight change), a flow rate change, a drill pipe rotation change, or the use of RFID (radio frequency identification) technology.

[0046] refer to Figure 7 , opening valve 46 places filter 36 in a flushing mode in which fluid communication is established between outer cavity 38 and fluid port 44 . Figure 7 The arrows in the figure show the flow path of the fluid through the filter 36 in the flushing mode. Specifically, the fluid that is allowed to flow through the outer cavity 38 flows through the fluid port 44 and exits through the flushing outlet 28, and then flows into the annular space 48. This fluid flow flushes the collected solids contained in the outer cavity 38 out of the filter 36 and releases the collected solids into the annular space 48 through the flushing outlet 28. Therefore, the filter 36 does not need to be removed from the wellbore to remove the collected solids, nor does the filter 36 release the collected solids into the drive mechanism 24 or bottom hole assembly downstream of the separation device 22. Optionally, the filter 36 can allow fluid to flow through the central cavity 58 and the fluid outlet 60 in the flushing mode.

[0047] Reference now Figure 8, the separation device 22 may alternatively include a filter 64. The filter 64 includes an inner cavity 66 extending from a fluid inlet 68 to a central block 69, which contains a fluid port 70. The fluid port 70 leads to a flush outlet 28, which leads to an annular space 48 surrounding an outer surface 72 of the filter 64 and within the wellbore or casing 52. A valve 74 is configured to open and close the fluid port 70. A filter surface 76 forms an outer boundary of the inner cavity 66 and an inner boundary of an outer cavity 78, which extends from an upper block 80 to a fluid outlet 82. An opening in the filter surface 76 extends from the inner cavity 66 to the outer cavity 78. Figure 8 The arrows in the figure show the flow path of the fluid through the filter 64 in the filtering mode when the valve 74 is closed. Specifically, the fluid enters the filter 64 through the fluid inlet 68 and flows through the inner cavity 66, through the openings in the filter surface 76, through the outer cavity 78, and through the fluid outlet 82. When the fluid flows through the openings of the filter surface 76, all or a portion of the solid particles contained in the fluid are retained in the inner cavity 66. Over time, the solid particles gather in the inner cavity 66 and begin to fill the inner cavity 66. In some embodiments, the valve 74 opens automatically in response to an automatic trigger. For example, when a predetermined fluid pressure increase is reached in response to filling the inner cavity 66, the valve 74 can open. In other embodiments, the valve 74 opens in response to a signal received from the wellbore surface.

[0048] refer to Fig. 9 , opening valve 74 places filter 64 in a flushing mode in which fluid communication is established between lumen 66 and fluid port 70 . Fig. 9 The arrows in illustrative embodiments show the flow path of fluid through the filter 64 in the flushing mode. Specifically, fluid flowing through the inner cavity 66 is allowed to flow through the fluid port 70, exit through the flushing outlet 28, and enter the annular space 48. This fluid flow flushes the collected solids contained in the inner cavity 66 out of the filter 64 and releases the collected solids into the annular space 48 through the flushing outlet 28. Similar to the filter 36, the filter 64 does not need to be removed from the wellbore to remove the collected solids, nor does the filter 64 release the collected solids into the drive mechanism 24 or bottom hole assembly downstream of the separation device 22. Optionally, the filter 64 can allow fluid to flow through the outer cavity 78 and the fluid outlet 82 in the flushing mode.

[0049] Reference now Fig.10, the separation device 22 may alternatively include a filter 86. The filter 86 includes a housing 88, a piston 90 slidably disposed within the housing 88, and a filter surface 92 disposed within the housing 88 and concentrically surrounding the piston 90. The housing 88 includes an upper bridge portion 94 and a lower bridge portion 96 extending across the inner diameter. The upper bridge portion 94 and the lower bridge portion 96 each include a central hole configured to receive the piston 90 and a fluid channel 98 arranged along the periphery parallel to the central hole. The housing 88 also includes an inlet chamber 100 upstream of the upper bridge portion 94, an outer filter chamber 102 extending from the upper bridge portion 94 to the lower bridge portion 96 and surrounding the filter surface 92, an inner filter chamber 103 extending from the upper bridge portion 94 to the lower bridge portion 96 between the piston 90 and the filter surface 92, and an outer chamber 104 downstream of the lower bridge portion 96. The opening in the filter surface 92 fluidly connects the inner filter chamber 103 and the outer filter chamber 102. The housing 88 also includes a flush outlet 28 from the outlet chamber 104. The piston 90 includes an upper block 106 surrounding a portion of a piston inlet chamber 108; a lower block 110 surrounding a portion of a piston outlet chamber 112; and a center block 114 extending between and separating the piston inlet chamber 108 and the piston outlet chamber 112. The upper block 106 and the lower block 110 of the piston 90 each have a diameter that is extended relative to the center block 114. The piston 90 includes an upper port 116 surrounding the piston inlet chamber 108 and a lower port 118 surrounding the piston outlet chamber 112. Fig.10 In the illustrated filtering mode, the upper port 116 is received in the central hole of the upper bridge 94 (i.e., the upper port 116 is "closed"), the fluid passage 98 in the upper bridge 94 fluidly connects the inlet chamber 100 and the filter outer chamber 102 (i.e., the upper fluid passage 98 is "open"), the lower port 118 fluidly connects the inner filter chamber 103 to the piston outlet chamber 112 (i.e., the lower port 118 is "open"), and the lower block 110 engages and blocks the fluid passage 98 in the lower bridge 96 and the flushing outlet 28 (i.e., the lower fluid passage 98 and the flushing outlet are "closed"). Optionally, the filter 86 may also include a coupling 120 that connects the control unit 122 to the piston 90.

[0050] Fig.10The arrows in the figure show the filtration flow path of the fluid through the filter 86 in the filtration mode. Specifically, the fluid enters the filter 86 through the inlet chamber 100, flows through the fluid channel 98, flows through the external filter chamber 102, flows through the opening in the filter surface 92, flows through the internal filter chamber 103, the lower port 118 of the piston 90, the piston outlet chamber 112 and the outlet chamber 104. When the fluid flows through the opening of the filter surface 92, all or a portion of the solid particles contained in the fluid are retained in the external filter chamber 102. Over time, the solid particles accumulate in the external filter chamber 102 and begin to fill the external filter chamber 102. In some embodiments, the piston 90 automatically slides downward in response to an automatic trigger. For example, the piston 90 can slide in the downstream direction in response to a predetermined fluid pressure or in response to an increase in the fluid pressure of the filling of the external filter chamber 102. In other embodiments, the piston 90 slides in the downstream direction in response to a signal received from the wellbore surface, a signal received from the control unit 122, or a combination thereof.

[0051] refer to Fig.11 , the piston 90 moves downstream into the flushing mode to close all open ports in the filter 86 and open all closed ports in the filter 86: the upper block 106 engages and blocks the upper fluid passage 98 in the upper bridge portion 94 (i.e., closes the upper fluid passage), opens the upper port 116 of the piston 90, closes the lower port 118 of the piston 90 by positioning the lower port 118 in the central hole of the lower bridge portion 96, opens the lower fluid passage 98 in the lower block 110, and opens the flushing outlet 28. Fig.11 The arrows in the figure show the flushing flow path of the fluid through the filter 86 in the flushing mode. Specifically, the fluid entering the filter 86 through the inlet chamber 100 flows through the piston inlet chamber 108, the upper port 116, the inner filter chamber 103, the opening in the filter surface 92, the outer filter chamber 102, the fluid passage 98 in the lower bridge portion 96, the outlet chamber 104 and the filter port 28, and then flows into the annular space 48 between the outer surface 124 of the housing 88 and the wellbore or casing 52. The fluid flow flushes the collected solids contained in the outer filter chamber 102, wherein the fluid flow passes through the lower fluid passage 98 and exits the filter 86 through the flushing outlet 28 into the annular space 48. Therefore, the filter 86 does not need to be removed from the wellbore to remove the collected solids, nor does the filter 86 release the collected solids into the drive mechanism 24 downstream of the separation device 22. Discharging the collected solids into the annular space 48 enables the drilling system 20 to use a drive mechanism 24 that does not include any high temperature sensitive materials (such as all metal parts).

[0052] Reference now Fig.12The drive mechanism 24 of the drilling system 20 may include a positive displacement motor having a rotor 130 disposed within a stator profile 132, which is secured within a stator housing 134. The rotor 130, the stator profile 132, and the stator housing 134 may all be formed from one or more metallic materials. For example, the rotor 130, the stator profile 132, and the stator housing 134 may form a Moyno motor. Fig.13 In another embodiment shown, the positive displacement motor includes a rotor 130 disposed within a stator 136, which includes a stator profile formed integrally with a stator housing. In other embodiments, the drive mechanism 24 of the drilling system 20 may include any other positive displacement motor, such as a vane motor, a screw motor, a gear motor, or a lobe or roots motor. In some embodiments, the positive displacement motor of the drive mechanism 24 is elastomer-free.

[0053] refer to Fig.14 and Fig.15 , the drive mechanism 24 of the drilling system 20 may include a positive displacement motor that does not contain an elastomer. The positive displacement motor may be a vane motor having a rotor 140 disposed within a stator housing 142 and within a stator profile 144, and rollers 146 sized to fit into a cavity in an outer surface of the rotor 140. For example, the rotor 140, the stator housing 142, the stator profile 144, and the rollers 146 may form a vane motor. In a filtering mode, at least a portion of any solids contained in the drilling medium flowing through the separation device 22 is filtered out, so that when the drilling medium flows through the space between the rotor 140 and the stator profile 144 and the stator housing 142 in the vane motor, the drilling medium contains a smaller amount or volume of solids and smaller size solids. In certain embodiments, the positive displacement motor is elastomer-free.

[0054] Fig.16 and Fig.17 An embodiment of the drilling system 20 is shown in which the drive mechanism 24 includes a turbine motor. The turbine motor may include a housing 147 that houses a plurality of rotor blades 148 distributed around a central axis 149. The rotor blades 148 are configured to rotate so that the central axis 149 moves along the Fig.17 The turbine motor rotates in the direction of the arrow in the figure. The turbine motor uses the drilling medium flowing through the tool to rotate the central shaft 149 (i.e., converts hydraulic horsepower or pneumatic horsepower into mechanical horsepower). In the filtering mode, at least a portion of any solids contained in the drilling medium flowing through the separation device 22 are filtered out, so that when the drilling medium flows through the space between the rotor blades 148 and the housing 147 in the turbine motor, the drilling medium contains a smaller amount or volume of solids and smaller size solids, thereby reducing the risk of damage or failure of the turbine motor.

[0055] Fig.18 and Fig.19 An embodiment of the drilling system 20 is shown in which the drive mechanism 24 includes a friction reduction tool. The friction reduction tool may include a rotor 150 disposed within a stator 152. A valve 154 may be fixed to the downstream end of the rotor 150. The valve 154 includes a flow path 156, Fig.18 In the open valve position shown in FIG. 1 , flow path 156 leads to flow path 158 in stationary valve 160. Flow path 156 is Fig.19 150 and the stationary valve 160. In the closed valve position, the drilling medium is blocked from flowing through the flow path 158 of the stationary valve 160. In other words, the friction reduction tool uses the drilling medium flowing through the tool to rotate the rotor 150 (i.e., convert hydraulic horsepower or pneumatic horsepower into mechanical horsepower), which causes the valve 154 to transition between the open valve position and the closed valve position. In the filtering mode, at least a portion of any solids contained in the drilling medium flowing through the separation device 22 are filtered out, so that when the drilling medium flows between the rotor 150 and the stator 152 in the friction reduction tool, the drilling medium contains a smaller amount or volume of solids and smaller size solids, thereby reducing the risk of damage or failure of the friction reduction tool.

[0056] Fig. 20 and Fig.21 An embodiment of a drilling system 20 is shown in which the drive mechanism 24 includes a hammer device. The hammer device may include a housing 162 containing a mandrel 164 and one or more pistons 166 slidably disposed in an annular space between the mandrel 164 and the housing 162. The downstream surface of each piston 166 may serve as a hammer face 168, and the upstream-facing shoulder of the mandrel 164 may serve as an anvil face 170. The hammer device uses the drilling medium flowing therethrough to slide the pistons 166 in a downstream direction (i.e., converting hydraulic or pneumatic horsepower into mechanical horsepower) until the hammer face 168 of each piston 166 creates an impact when striking the anvil face 170 of the mandrel 164. In the filtering mode, at least a portion of any solids contained in the drilling medium flowing through the separation device 22 is filtered out, so that when the drilling medium flows through the hammer device, the drilling medium contains a smaller amount or volume of solids and smaller size solids, thereby reducing the risk of turbine motor damage or failure.

[0057] In each of these embodiments, the drive mechanism 24 need not include any elastomeric components or any other high temperature sensitive materials, which enables the drive mechanism 24 to operate at temperatures above 320° F. In certain embodiments, the drive mechanism 24 is configured to operate at temperatures between 320° F. and 1110° F., or any sub-range therein.

[0058] Reference now Fig. 22 , the drilling system 20 may be secured to the distal end of a coiled tubing string 180 by a coiled tubing connector 182 for use in drilling a wellbore 184 extending through a subterranean formation 188 below a surface 186. In this embodiment, an MWD tool 189 may be positioned between the coiled tubing connector 182 and the separation device 22, with the drive mechanism 24 and a drill bit or milling cutter 190 positioned downstream. Drilling medium may be pumped through the coiled tubing string 180 and the coiled tubing connector 182. When the drilling medium flows through the separation device 22 in a filtering mode (i.e., a default mode), all or a portion of the solid particles within the drilling medium are removed and collected within the separation device 22. Clean drilling medium (i.e., the remaining liquid or gas components) flows downstream through the drive mechanism 24 and the drill bit 26. In an embodiment of the separator 22 that is activated in response to an automatic trigger, the separator 22 can be placed in a flushing mode when the separator 22 reaches a predetermined threshold volume or a predetermined amount of collected solids and the upstream fluid pressure increases by a predetermined amount. In the flushing mode, the separator 22 uses the flow of the drilling medium to flush the collected solid particles out of the separator 22 through the flushing outlet 28 and into the annular space 192 between the drilling system 20 and the formation 188. Once the upstream fluid pressure drops below a predetermined deactivation value, the separator 22 can automatically switch back to the filtering mode so that the solid particles are collected from the drilling medium flowing through the separator 22, and the clean drilling medium then flows through the drive mechanism 24. The separator 22 can also be placed in the filtering mode or the flushing mode in response to a signal received from the surface of the wellbore. Such a signal can be, but is not limited to, a pressure pulse sequence (mud weight change), a flow rate change, a drill pipe rotation change, or the use of RFID (radio frequency identification) technology.

[0059] refer to Fig.23 , the drilling system 20 can be fixed to the distal end of the drill string 194 for drilling the wellbore 184. In this embodiment, the MWD tool 189 can be positioned upstream of the separator 22, and the drive mechanism 24 and the drill bit 26 are positioned downstream. The drive mechanism 24 can include a curved housing drilling motor. The drilling medium flowing through the drill string 194 can flow through the separator 22 before reaching the drive mechanism 24 and the drill bit 26. The separator 22 in the filtering mode can remove some or all of the solid particles in the drilling medium. Fig. 22In the same manner, when the solid particles collected in the separator 22 cause the upstream fluid pressure to reach a predetermined activation value, the separator 22 is activated and placed in the flushing mode. When activated, the fluid flowing through the separator 22 flushes the collected solids through the flushing outlet 28 and enters the annular space 192 between the drilling system 20 and the formation 188. After deactivation, the fluid flowing through the separator 22 in the filtering mode is cleaned again before entering the drive mechanism 24.

[0060] Fig.24 An alternative embodiment of a drilling system 20 fixed to the distal end of a drill string 194 for drilling a wellbore 184 is shown. In this embodiment, an MWD tool 189 can be positioned downstream of both the separator 22 and the drive mechanism 24. The drilling system 20 can include a steering mechanism 32 disposed between the MWD tool 189 and the drill bit 26. The steering mechanism 32 can be a rotary steerable system. In this embodiment, the separator 22 in a filtering mode removes all or part of the solid particles from the drilling medium before the drilling medium reaches the drive mechanism 24. When a predetermined amount of solids is collected, the separator 22 is activated to enter a flushing mode. In the flushing mode, fluid flushes the collected solids into the annular space 192 between the drilling system 20 and the underground formation 188 through the flushing outlet 28. The separator 22 is then deactivated and placed in a filtering mode to again remove and collect solid particles from the drilling medium.

[0061] Alternatively, if Figure 22 to Figure 24 The separation device 22 used as shown can be activated and switched to the flushing mode in response to a signal from the surface. For example, the signal can be a pressure pulse, an electrical signal, a magnetic signal, a mechanical signal (rotation speed change, weight-on-bit (WOB) change, axial movement of the drill pipe, etc.) or any other type of signal that can be detected in the wellbore 184.

[0062] like Fig.25 As shown, when drilling a wellbore 184, two or more drilling systems 20 can be used in a drill string 194. An upstream drilling system 20A can be fixed to the downstream end of the drill string 194, and a pipe string 196 can be fixed between the upstream drilling system 20A and the downstream drilling system 20B. The upstream drilling system 20A includes a separation device 22A and a drive mechanism 24A, and the downstream drilling system 20B includes a separation device 22B and a drive mechanism 24B. The drive mechanism 24B can be configured to drive the drill bit 190, and the drive mechanism 24A can be configured to generate vibrations, activate valves or any actuating devices, or provide power for a generator. For example, the drive mechanism 24B can include a positive displacement motor (e.g., a vane motor or a Moyno motor), a turbine, an impact motor or a hammer, and the drive mechanism 24A can include a turbine, a friction reduction tool or a vibration generating tool.

[0063] Figure 26 to Figure 29 The interaction of the mode of the downstream separator 22B relative to the mode of the upstream separator 22A is shown. In the illustrated embodiment, the separators 22A and 22B all include the same features and functions described above in conjunction with the filter 86. In some embodiments, the separators 22A and 22B are configured to independently activate from the filtering mode to the flushing mode in response to an automatic activation trigger (e.g., a predetermined pressure drop) or in response to a signal from the surface. For example, each separator 22A can be configured to respond to a surface signal A and a surface signal C, and the separator 22B can be configured to respond to a surface signal B and a surface signal C. In this way, the surface signal can activate only the separator 22A, only the separator 22B, or both the separators 22A and 22B. In other embodiments, the separators 22A and 22B are configured to activate simultaneously in response to all the same automatic activation triggers and / or the same signal from the wellbore surface.

[0064] Reference now Fig.25 and Fig.26 , shows the separators 22A and 22B in filtering mode. In this mode, the drilling medium flows through the filtering flow path in the upstream separator 22A: through the fluid channel 98A, through the openings in the filtering surface 92A, through the lower port 118A and to the drive mechanism 24A. The solid portion from the drilling medium collected by the separator 22A is retained, so that the solid content and the size of the solids of the drilling medium are reduced before entering the drive mechanism 24A. After flowing through the drive mechanism 24A, the drilling medium flows through the tubing string 196 and the MWD device 189, and then enters the downstream separator 22B. In the filtering mode shown, the drilling medium flows through the filtering flow path in the downstream separator 22B: through the fluid channel 98B, through the openings in the filtering surface 92B, through the lower port 118B and to the drive mechanism 24B. The solid portion from the drilling medium collected by the separator 22B is retained, so that the solid content and the size of the solids of the drilling medium are reduced before entering the drive mechanism 24B. After flowing through drive mechanism 24B, the drilling medium flows to drill bit 190 .

[0065] refer to Fig.25 and Fig. 27, the upstream separator 22A can be activated alone to flush collected solids from the upstream separator 22A into the annular space 192. In the full flush mode of the separator 22A shown, no appreciable amount of drilling medium flows to the downstream separator 22B. Instead, substantially all of the drilling medium that flows into the upstream separator 22A flows through its flushing flow path: through the upper port 116A, through the openings in the filter surface 92A, through the fluid passage 98A, and out of the separator 22A through the flushing outlet 28A. In this mode, the drilling medium flushes the collected solids out of the separator 22A and into the annular space 192. When the separator 22A is in the full flush mode, no drilling medium flows downstream beyond the separator 22A. When the upper separator 22A is in this mode, the mode of the downstream separator 22B has no effect on the drilling medium flow.

[0066] Reference now Fig.25 and Fig.28 , the downstream separator 22B can be activated to a full flushing mode while the upstream separator 22A remains in a filtering mode to flush only from the downstream separator 22B. The drilling medium that flows into the upstream separator 22A flows through the filtering flow path and flows to the upstream drive mechanism 24A. After flowing through the tubing string 196 and the MWD 189, the drilling medium flows into the downstream separator 22B. Substantially all of the drilling medium flows through the flushing flow path of the separator 22B: through the upper port 116B, the opening in the filtering surface 92B, the fluid passage 98B, and exits the separator 22B through the flushing outlet 28B.

[0067] refer to Fig.25 and Fig.29 , separators 22A and 22B may be activated to flush mode simultaneously. For example, upper separator 22A may be placed in a partial flush mode, wherein a portion of the drilling medium entering separator 22A flows through its flush flow path to flush collected solids into annular space 192 through flush outlet 28A. The remainder of the drilling medium entering separator 22A flows through its filter flow path and flows through upstream drive mechanism 24A, through tubing string 196, through MWD 189, and into downstream separator 22B. Fig.29 In the illustrated embodiment, the downstream separation device 22B has been activated in a full flush mode such that substantially all of the drilling medium entering the separation device 22B flows through its flush flow path and exits through the flush outlet 28B into the annular space 192. Alternatively, the downstream separation device 22B may be placed in a partial flush mode while the upstream separation device 22A is in a partial flush mode such that a portion of the drilling medium flows toward the downstream drive mechanism 24B and the drill bit 190.

[0068] As used herein, "drive mechanism" means any device or tool capable of converting hydraulic horsepower or pneumatic horsepower into mechanical horsepower (for example, but not limited to, mechanical horsepower for driving a drill or milling cutter, powering a generator, activating a valve, activating any actuating device, or producing vibration or shock).

[0069] As used herein, "elastomer" means any material having the properties of an elastic material, such as, but not limited to, a polymer that is able to return to its original shape after being stretched, shrunk, expanded, or deformed.

[0070] As used herein, "elastomer-free" when referring to a mechanism or tool means that the mechanism or tool has no parts formed from any elastomer.

[0071] As used herein, "high temperature sensitive material" refers to a material that degrades, decomposes, melts, or undergoes at least one mechanical property change at temperatures above 320°F, or at temperatures between 320°F and 1110°F, or any subrange therein, to an extent that the material becomes unusable in a drilling system.

[0072] As used herein, "drilling medium" means any liquid or compressible gas, which may include solid particles.

[0073] Unless otherwise described or illustrated, each component in the apparatus has a generally cylindrical shape and may be formed from steel, another metal, or any other durable material. Portions of the drilling system 20 may be formed from wear-resistant materials such as tungsten carbide, ceramic, or ceramic-coated steel.

[0074] Each device described in the present disclosure may include any combination of the described parts, features and / or functions of each embodiment in each device embodiment. Each method described in the present disclosure may include any combination of the steps described in any order, including a combination of steps lacking certain descriptions and steps used in separate embodiments. Any numerical range disclosed herein includes any sub-range within the range. "Plurality" means two or more. "Above" and "below" should each be understood to mean upstream and downstream, so that the directional orientation of the device is not limited to a vertical arrangement.

[0075] While preferred embodiments have been described, it should be understood that these embodiments are merely illustrative and that the scope of the invention will be limited only by the appended claims (when given the full scope of equivalents, the numerous variations and modifications that would naturally occur to one skilled in the art upon review of the invention).

Claims

1. A drilling system for drilling a wellbore, comprising: Driving mechanism; a separation device disposed upstream of the drive mechanism; The separation device includes a filtration flow path and a flushing flow path; wherein the flushing flow path extends to a flushing outlet on an outer surface of the separation device; wherein the separation device is configured to filter at least a portion of any solids from the drilling medium flowing through the filter flow path; and Wherein, the separation device is configured to flush at least a portion of the filtered solids through the flushing outlet and out of the outer surface of the separation device when the drilling medium flows through the flushing flow path.

2. The drilling system according to claim 1, wherein: The separation device is configured to direct the drilling medium through the filtration flow path in a filtration mode; wherein activation of the separation device places the separation device in a flushing mode; wherein the separation device is configured to direct at least a portion of the drilling medium through the flushing flow path and the flushing outlet in the flushing mode.

3. The drilling system according to claim 2, wherein: The separation device is activated in response to a signal from the surface of the wellbore.

4. The drilling system according to claim 2, wherein: The disconnect device is automatically activated in response to an automatic trigger.

5. The drilling system according to claim 2, wherein: In the flush mode, the separator prevents all of the drilling medium from flowing to the drive mechanism.

6. The drilling system according to claim 2, wherein: In the flushing mode, the separation device allows a portion of the drilling medium to flow to the drive mechanism.

7. The drilling system according to claim 1, wherein: The filter flow path extends from a dirty side of a filter surface to a clean side of the filter surface; and wherein the flush flow path extends from the clean side of the filter surface to the dirty side of the filter surface.

8. The drilling system according to claim 1, wherein: The drive mechanism includes a positive displacement motor.

9. The drilling system according to claim 8, wherein: The positive displacement motor is a Moyno motor or a vane motor.

10. The drilling system according to claim 1, wherein: The drive mechanism includes a turbine.

11. The drilling system according to claim 1, wherein: The driving mechanism includes a hammer device or a vibration generating device.

12. The drilling system according to claim 1, wherein: The drive mechanism includes friction reducing means.

13. The drilling system of claim 1, wherein: The drive mechanism includes a steerable drilling motor including a bent joint.

14. The drilling system of claim 1, wherein: The drive mechanism includes a rotationally steerable system.

15. The drilling system of claim 1, wherein: Neither the drive mechanism nor the separation device comprises any high temperature sensitive material.

16. The drilling system of claim 1, further comprising: a second driving mechanism; and a second separation device disposed upstream of the second drive mechanism; The second separation device includes a filtration flow path and a flushing flow path; wherein the flushing flow path extends to a flushing outlet on an outer surface of the second separation device; wherein the second separation device is configured to filter at least a portion of any solids from the drilling medium flowing through the filter flow path; and The second separation device is configured to flush at least a portion of the filtered solids through the flushing outlet and out of the outer surface of the second separation device when the drilling medium flows through the flushing flow path.

17. The drilling system of claim 16, wherein: The separation device and the second separation device are each configured to guide the drilling medium through the filtration flow path in a filtration mode; wherein activation of the separation device places the separation device in a flushing mode; wherein activation of the second separation device places the second separation device in a flushing mode; wherein the separation device and the second separation device are each configured to guide at least a portion of the drilling medium through the flushing flow path and the flushing outlet in the flushing mode.

18. The drilling system of claim 17, wherein: The separation device and the second separation device are each activated in response to one or more signals from the surface of the wellbore.

19. The drilling system of claim 17, wherein: The separating device and the second separating device are each automatically activated in response to an automatic trigger.

20. The drilling system of claim 17, wherein: The separation device and the second separation device are configured to be activated simultaneously or sequentially.

21. The drilling system of claim 17, wherein: The separation device and the second separation device are configured to be independently activated.

22. A method of drilling a wellbore, comprising the steps of: a) providing a drilling system, the drilling system comprising: a driving mechanism and a separation device disposed upstream of the driving mechanism; the separation device comprising a filtering flow path and a flushing flow path; wherein the flushing flow path extends to a flushing outlet on an outer surface of the separation device; b) drilling a wellbore in a subterranean formation using the drilling system; c) flowing drilling medium through the filter flow path of the separation device to filter at least a portion of any solids within the drilling medium; wherein any filtered solids are retained within the separation device; d) causing the drilling medium to flow to the drive mechanism; and e) activating the separator device to cause the drilling medium to flow through the flushing flow path of the separator device so that at least a portion of the filtered solids are flushed through the flushing flow path and into the annular space between the outer surface of the separator device and the wellbore through the flushing outlet.

23. The method according to claim 22, wherein: In step (e), the separation device is activated in response to a signal from the surface of the wellbore.

24. The method of claim 22, wherein in step (e), the separation device is automatically activated in response to an automatic trigger.

25. The method according to claim 22, further comprising the steps of: f) deactivating the separation device to allow the drilling fluid to flow through the filtered flow path; in Steps (b) to (e) are performed without removing the separation device from the wellbore.

26. The method of claim 22, wherein: Neither the drive mechanism nor the separation device comprises any high temperature sensitive material.

27. The method of claim 22, wherein in step (a), the drilling system further comprises: a second drive mechanism and a second separation device disposed upstream of the second drive mechanism; The second separation device includes a filtration flow path and a flushing flow path; wherein the flushing flow path extends to a flushing outlet on an outer surface of the second separation device; wherein the second drive mechanism and the second separation device are arranged downstream of the drive mechanism; and the method further comprises the following steps: f) flowing the drilling medium through the filter flow path of the second separation device to filter at least a portion of any solids in the drilling medium; wherein any filtered solids are retained in the second separation device; g) flowing the drilling medium to the drive mechanism; and h) activating the second separation device to cause the drilling medium to flow through the flushing flow path of the second separation device to flush at least a portion of the filtered solids through the flushing flow path and into the annular space through the flushing outlet.

28. The method according to claim 27, wherein: Step (e) and step (h) occur simultaneously or sequentially.

29. The method according to claim 27, wherein: Step (e) and step (h) occur independently.

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