Drilling system and method with annular washout separation device

Abstract

A drilling system for use in drilling a well bore 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 media flowing through a filter flow path of the separation device. The separation device washes at least a portion of the filtered solids through a washout outlet, through a washout outlet on an outer surface of the separation device, and into an annulus between the outer surface of the separation device and the well bore. Optionally, the drilling system includes a second drive mechanism and a second separation device disposed above the second drive mechanism.

Description

[Background technology]

[0001] In the process of drilling and maintaining a wellbore, drilling fluid is pumped through drilling motors, such as positive displacement motors, and other drilling and completion equipment, such as friction reduction tools, percussion hammers, and turbines. Most drilling fluids contain solid particles (e.g., weighted materials such as barite and hematite, low-gravity solids such as bentonite clay, crushed rock, and cuttings). Some pieces of drilling and completion equipment are sensitive to solid particles in the drilling fluid. For example, some drilling motors contain only metal components that are not capable of flexing when the drilling fluid containing the solid particles flows between the components. Instead, solid particles often become wedged between two metal components, which causes the drilling motor to wear prematurely or stop rotating, thereby rendering the metal-metal drilling motor inoperable. The power section of other drilling motors contains an elastomeric material that flexes to allow solid particles to flow through the drilling motor. However, these elastomeric materials can begin to deteriorate or fail when the drilling motor is exposed to high temperatures in the wellbore or to oil-based drilling fluids with low aniline points.

[0002] In both cases, a filter is sometimes positioned upstream of the drilling motor to reduce the amount of solid particles in the drilling fluid before it enters the drilling motor. However, the filter has a limited capacity for collected solid particles and fills after some time. Once the filter reaches capacity, some conventional filters direct the drilling fluid through passages within the filter, bypassing the solid particle capture section of the filter, thereby allowing unfiltered drilling fluid to reach the downstream drilling motor while retaining any solid particles contained in the solid particle capture section of the filter.

[0003] 1 and 2 illustrate an example of a conventional filter 2. Fluid flowing through the filter 2 is directed to flow through the filter surface 4 to collect solid particles within the filter sleeve 6. When a predetermined amount of solid particles is retained within the filter sleeve 6, the associated pressure drop causes the shear pins 8 to break and release the filter sleeve 6, which moves downstream and opens the bypass port 10, as shown in FIG. 2. In this position, fluid flow through the filter 2 is allowed to continue as the filter sleeve 6 fills with solid particles. However, the fluid flowing through the bypass port 10 is unfiltered, increasing the likelihood that the solid particles will damage a downstream drilling motor.

[0004] To clear the collected solid particles from the filter, conventional filters are typically withdrawn from the drill string for cleaning. For example, filter 2 in FIGS. 1 and 2 is required to be withdrawn from the drill string to remove the collected solid particles before the fluid can be filtered again. Removing the filter from the well requires the user to stop drilling operations, resulting in lost drilling time and increased drilling costs. Alternatively, the collected solid particles can be cleared from the filter by opening the solid particle collection section of the filter and flushing the collected solid particles downstream through a central fluid path with the flow of drilling fluid to the drilling motor. Flushing the collected solid particles downstream with drilling fluid increases the amount of solid particles flowing through the drilling motor, which increases the likelihood that solid particles will become wedged between two metal components in a metal-metal drilling motor, thereby increasing the likelihood that the drilling motor will prematurely wear out or stop operating completely.

[0005] Therefore, conventional filters and metal-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 any solids, which is not convenient in most drilling applications. In applications involving solid particles in the drilling fluid, drilling motors with elastomeric components are typically used. However, some elastomeric materials begin to decompose at high temperatures, such as temperatures above 320°F, and drilling tools are exposed to such high temperatures in certain sections (i.e., hot sections) of some underground wells. In wells that pass through hot sections, metal-metal drilling machines are the only option.

[0006] A need exists for a drilling system that filters solid particles from a drilling fluid and sweeps the collected solid particles from the filter without removing the system or filter from the wellbore and without releasing the collected solid particles through the drilling machine. A further need exists for a drilling system that allows for the effective use of solid particles in the drilling fluid even when the drilling system is exposed to high temperatures. Summary of the Invention [Means for solving the problem]

[0007] Disclosed herein is a drilling system that includes a drive mechanism and a separation device that is self-cleaning by washing collected solids into an annulus around the outer surface of the separation device, wherein neither the drive mechanism nor the separation device includes any high temperature sensitive materials. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view of a prior art filter device in a filtering position.

[0009] [Figure 2] FIG. 2 is a cross-sectional view of the prior art filter device shown in FIG. 1 in the bypass position.

[0010] [Figure 3] FIG. 3 is a front view of the excavation system of the present disclosure.

[0011] [Figure 4] FIG. 4 is a schematic diagram of fluid flow through a separation device of a drilling system in filter mode.

[0012] [Figure 5] FIG. 5 is a schematic diagram of fluid flow through a separation device of a drilling system in an activated mode.

[0013] [Figure 6] FIG. 6 is a cross-sectional view of one embodiment of a separation device of a drilling system in a filter mode.

[0014] [Figure 7] FIG. 7 is a cross-sectional view of the separation device of FIG. 6 in an activated mode.

[0015] [Figure 8] FIG. 8 is a cross-sectional view of an alternative embodiment of a separation device of a drilling system in a filter mode.

[0016] [Figure 9] FIG. 9 is a cross-sectional view of the separation device of FIG. 8 in an activated mode.

[0017] [Figure 10] FIG. 10 is a cross-sectional view of another alternative embodiment of a separation device for a drilling system in a filter mode.

[0018] [Figure 11] FIG. 11 is a cross-sectional view of the separation device of FIG. 10 in an activated mode.

[0019] [Figure 12]FIG. 12 is a partial cutaway view of an embodiment of a drilling system in which the drive mechanism includes a Moyno motor with a metal stator profile.

[0020] [Figure 13] FIG. 13 is a partial cutaway view of an embodiment of a drilling system in which the drive mechanism includes a Moyno motor with a metal stator profile integrally formed with the stator housing.

[0021] [Figure 14] FIG. 14 is a partial front view of an embodiment of a drilling system in which the drive mechanism includes a vane motor.

[0022] [Figure 15] FIG. 15 is a cross-sectional view taken along line 15-15 in FIG.

[0023] [Figure 16] FIG. 16 is a partial front view of an embodiment of a drilling system in which the drive mechanism includes a turbine motor.

[0024] [Figure 17] FIG. 17 is a cross-sectional view taken along line 17-17 in FIG.

[0025] [Figure 18] FIG. 18 is a partial cutaway view of an embodiment of a drilling system in which the drive mechanism includes a friction reducing implement in an open valve position.

[0026] [Figure 19] FIG. 19 is a partial cutaway view of the embodiment of the drilling system shown in FIG. 18 with the friction reducing implement in a closed valve position.

[0027] [Figure 20] FIG. 20 is a partial cutaway view of an embodiment of a drilling system in which the drive mechanism includes a hammer device in a first position.

[0028] [Figure 21] FIG. 21 is a partial cutaway view of the embodiment of the drilling system shown in FIG. 20 with the hammer device in a second position.

[0029] [Figure 22] FIG. 22 is a schematic diagram of an embodiment of a drilling system positioned within a subterranean well using a coiled tubing string.

[0030] [Figure 23] FIG. 23 is a schematic diagram of an embodiment of a drilling system including a bending motor positioned within a subterranean well using a tubular drill string.

[0031] [Figure 24] FIG. 24 is a schematic diagram of an embodiment of a drilling system including a rotary steerable system positioned within a subterranean well using a tubular drill string.

[0032] [Figure 25] FIG. 25 is a schematic diagram of an embodiment of a drilling system including two separation devices and two drive mechanisms.

[0033] [Figure 26] FIG. 26 is a cross-sectional view of an upstream separation device and a downstream separation device, both in a filter mode.

[0034] [Figure 27] FIG. 27 is a cross-sectional view of the upstream and downstream separation devices with the upstream separation device in full flush mode.

[0035] [Figure 28] FIG. 28 is a cross-sectional view of an upstream separation device in filter mode and a downstream separation device in wash mode.

[0036] [Figure 29]FIG. 29 is a cross-sectional view of an upstream separation device in partial flush mode and a downstream separation device in full flush mode. DETAILED DESCRIPTION OF THE INVENTION

[0037] Detailed Description of Selected Embodiments 3-29 illustrate several embodiments of the drilling system disclosed herein, and many other embodiments within the scope of the claims will be apparent to those of ordinary skill in the art after reviewing this disclosure.

[0038] Referring to FIG. 3 , drilling system 20 includes a separation device 22 connected upstream of a drive mechanism 24 connected upstream of a drill bit or crusher. Drive mechanism 24 may include any device that converts hydraulic or pneumatic horsepower into mechanical horsepower (including, but not limited to, for use in driving a bit or crusher, powering a generator, activating a valve, activating any operating device, or generating vibration or impact). For example, drilling mechanism 24 may include a positive displacement motor (e.g., vane motor, Moyno motor), a turbine, a friction reduction tool, a percussion motor, a vibration generating tool, and an impact generating tool. Separation device 22 is configured to remove at least a portion of solid particles contained in the fluid flowing through separation device 22 before it reaches drive mechanism 24. Non-limiting examples of solid particles that may be contained in the fluid include cuttings (e.g., rock particles), weighted material (e.g., barite), and scale from pipe. The separation device 22 is also configured, when activated, to release the collected solids through a washout outlet 28. Optionally, the drilling system 20 may also include a steering mechanism 32 disposed downstream from the drive mechanism 24.

[0039] In some embodiments, both separation device 22 and 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 devices and drive mechanism are configured to operate at temperatures between 320° F and 1,110° F, or any subrange therein. In some embodiments, all components of drive mechanism 24 are formed from one or more metallic materials.

[0040] 4 illustrates fluid flow through separation device 22 in filter mode. Fluid entering separation device 22 is directed to flow from the "dirty side" of the filter to the "clean side" of the filter. Filter media 34 retains solid particles on the "dirty side" while the fluid flows through filter media 34 to the "clean side." In filter mode, the cleaned fluid is directed downstream to a bottom hole assembly ("BHA"), which includes drive mechanism 24.

[0041] 5 illustrates fluid flow through separation device 22 in wash mode. Fluid entering separation device 22 is directed to flow from the "clean side" of the filter to the "dirty side" of the filter. The fluid washes some or all of the collected solid particles contained within separation device 22 through wash outlet 28 (shown in FIG. 3) into an annulus surrounding the outer surface of separation device 22.

[0042] Referring to FIG. 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 configured to open and close the fluid port 44. The fluid port 44 extends from the outer cavity 38 to a washout outlet 28, which opens to an annulus 48 that surrounds an outer surface 50 of the filter 36 and resides within a wellbore or casing 52. The filter 36 also includes a center block 54 that extends to a filter surface 56 that together form an inner boundary of the outer cavity 38. An opening in the filter surface 56 extends from the outer cavity 38 to the central cavity 58, which extends from the space within the filter surface 56 to a fluid outlet 60. The arrows in FIG. 6 illustrate the fluid flow path through the filter 36 in filter mode with the valve 46 closed. Specifically, fluid enters the filter 36 through the fluid inlet 40, flows through the outer cavity 38, through openings in the filter surface 56, through the central cavity 58, and through the fluid outlet 60. As the fluid flows through the openings in the filter surface 56, all or a portion of the solid particles contained within the fluid are retained within the outer cavity 38. Over time, the solid particles collect within 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 surface independent. For example, the valve 46 opens when a predetermined fluid pressure increases upstream of the filter surface 56 in response to filling of the outer cavity 38. In other embodiments, the valve 46 opens in response to a signal received from the surface of the wellbore. Such signals may be, but are not limited to, a sequence of pressure pulses (mud gravity change), flow rate changes, drill pipe rotation changes, or the use of RFID (Radio Frequency Identification) technology.

[0043] Referring to FIG. 7 , the open valve 46 places the filter 36 in a flushing mode, in which fluid communication is enabled between the outer cavity 38 and the fluid port 44. The arrows in FIG. 7 illustrate the fluid flow path through the filter 36 in the flushing mode. Specifically, fluid flowing through the outer cavity 38 is allowed to flow through the fluid port 44, exit through the flushing outlet 28, and then into the annulus 48. This fluid flow flushes collected solids contained within the outer cavity 38 out of the filter 36 and releases the collected solids through the flushing outlet 28 into the annulus 48. Thus, the filter 36 is not required 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 bottomhole assembly downstream of the separation device 22. Optionally, the filter 36 may allow fluid flow through the central cavity 58 and fluid outlet 60 in the flushing mode.

[0044] Referring now to FIG. 8 , separation device 22 may alternatively include filter 64. Filter 64 includes an inner cavity 66 extending from a fluid inlet 68 to a center block 69 containing a fluid port 70. Fluid port 70 leads to a washout outlet 28, which opens to an annulus 48, which surrounds an outer surface 72 of filter 64 and resides within wellbore or casing 52. Valve 74 is configured to open and close fluid port 70. Filter surface 76 forms an outer boundary of 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 filter surface 76 extends from inner cavity 66 to outer cavity 78. Arrows in FIG. 8 illustrate the fluid flow path through filter 64 in filter mode with valve 74 closed. Specifically, fluid enters filter 64 through fluid inlet 68, flows through inner cavity 66, through openings in filter surface 76, through outer cavity 78, and through fluid outlet 82. As the fluid flows through the openings in filter surface 76, all or a portion of the solid particles contained within the fluid are retained within inner cavity 66. Over time, the solid particles collect within inner cavity 66 and begin to fill inner cavity 66. In some embodiments, valve 74 automatically opens in response to an automatic trigger. For example, valve 74 may open when a predetermined fluid pressure increase is reached in response to filling inner cavity 66. In other embodiments, valve 74 opens in response to a signal received from the surface of the wellbore.

[0045] Referring to FIG. 9 , the open valve 74 places the filter 64 in a flush mode, in which fluid communication is allowed between the inner cavity 66 and the fluid port 70. The arrows in FIG. 9 illustrate the fluid flow path through the filter 64 in the flush mode. Specifically, fluid flowing through the inner cavity 66 is allowed to flow through the fluid port 70, exit through the flush outlet 28, and enter the annulus 48. This fluid flow flushes collected solids contained within the inner cavity 66 out of the filter 64 and releases the collected solids through the flush outlet 28 into the annulus 48. Similar to the filter 36, the filter 64 is not required 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 bottomhole assembly downstream of the separation device 22. Optionally, the filter 64 may allow fluid flow through the outer cavity 78 and fluid outlet 82 in the flush mode.

[0046] 10 , separation device 22 may alternatively include a filter 86. Filter 86 includes a housing 88, a piston 90 slidably disposed within housing 88, and a filter surface 92 disposed within housing 88 and concentrically surrounding piston 90. Housing 88 includes upper and lower bridge portions 94 and 96 extending across an inner diameter. Upper and lower bridge portions 94 and 96 each include a central bore configured to receive piston 90 and circumferentially arranged fluid passageways 98 that are parallel to the central bore. The housing 88 also includes an inlet cavity 100 upstream of the upper bridge portion 94, an outer filter cavity 102 extending from the upper bridge portion 94 to the lower bridge portion 96 and surrounding the filter surface 92, an inner filter cavity 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 outlet cavity 104 downstream of the lower bridge portion 96. An opening in the filter surface 92 fluidly connects the inner filter cavity 103 and the outer filter cavity 102. The housing 88 further includes a washout outlet 28 from the outlet cavity 104. The piston 90 includes an upper block 106 surrounding a portion of the piston inlet cavity 108, a lower block 110 surrounding a portion of the piston outlet cavity 112, and a center block 114 extending between and separating the piston inlet cavity 108 and the piston outlet cavity 112. The upper and lower blocks 106, 110 of the piston 90 each have an expanded diameter relative to the center block 114. The piston 90 includes an upper port 116 surrounding the piston inlet cavity 108 and a lower port 118 surrounding the piston outlet cavity 112.10 , the upper port 116 is retracted within the central bore 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 cavity 100 and the filter outer cavity 102 (i.e., the upper fluid passage 98 is “open”), the lower port 118 fluidly connects the inner filter cavity 103 to the piston outlet cavity 112 (i.e., the lower port 118 is “open”), and the lower block 110 engages and blocks the fluid passage 98 and the washout outlet 28 in the lower bridge 96 (i.e., the lower fluid passage 98 and the washout outlet 28 are “closed”). Optionally, the filter 86 may further include a coupler 120 connecting a control unit 122 to the piston 90.

[0047] The arrows in FIG. 10 illustrate the filter flow path of fluid through the filter 86 in filter mode. Specifically, fluid enters the filter 86 through the inlet cavity 100, flows through the fluid passage 98, through the outer filter cavity 102, through openings in the filter surface 92, through the inner filter cavity 103, the lower port 118 of the piston 90, the piston outlet cavity 112, and the outlet cavity 104. As the fluid flows through the openings in the filter surface 92, all or a portion of the solid particles contained within the fluid are retained within the outer filter cavity 102. Over time, the solid particles collect within the outer filter cavity 102 and begin to fill it. In some embodiments, the piston 90 automatically slides downward in response to an automatic trigger. For example, the piston 90 may slide downstream in response to a predetermined fluid pressure or an increase in fluid pressure in response to filling of the outer filter cavity 102. In other embodiments, the piston 90 slides downstream in response to a signal received from the wellbore surface, a signal received from the control unit 122, or a combination thereof.

[0048] 11 , downstream movement of piston 90 into the flush mode may close all open ports and open all closed ports within filter 86, i.e., upper block 106 engages, blocking upper fluid passage 98 in upper bridge 94 (i.e., closing the upper fluid passage), opening upper port 116 of piston 90, closing lower port 118 of piston 90 by positioning lower port 118 in the central bore of lower bridge 96, opening lower fluid passage 98 in lower block 110, and opening flush outlet 28. Arrows in FIG. 11 illustrate the flush flow path of fluid through filter 86 in the flush mode. Specifically, fluid entering filter 86 through inlet cavity 100 flows through piston inlet cavity 108, upper port 116, inner filter cavity 103, openings in filter surface 92, outer filter cavity 102, fluid passages 98 in lower bridge section 96, outlet cavity 104, and filter port 28, and then into annulus 48 between outer surface 124 of housing 88 and wellbore or casing 52. This fluid flow washes collected solids contained in outer filter cavity 102 out of filter 86 and through washout outlet 28 into annulus 48 with fluid flow through lower fluid passage 98. Thus, filter 86 is not required to be removed from the wellbore to remove collected solids, nor does filter 86 release collected solids into drive mechanism 24 downstream of separation device 22. Discharging collected solids into the annulus 48 allows the drilling system 20 to use a drive mechanism 24 that does not include any high temperature sensitive materials (such as all metal components).

[0049] Referring now to FIG. 12 , the drive mechanism 24 of the drilling system 20 may include a positive displacement motor having a rotor 130 disposed within a stator profile 132 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. In a further embodiment illustrated in FIG. 13 , the positive displacement motor includes the rotor 130 disposed within a stator 136, which includes a stator profile integrally formed with the 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.

[0050] 14 and 15, the drive mechanism 24 of the drilling system 20 may include an elastomer-free positive displacement motor. The positive displacement motor may be a vane motor having a rotor 140 disposed within a stator housing 142 and a stator profile 144 with rollers 146 sized to fit within cavities in the 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 the filter mode, at least a portion of any solids contained in the drilling medium flowing through the separation device 22 are filtered out so that the drilling medium contains a smaller amount or volume of solids and smaller sized solids as the drilling medium flows through the space between the rotor 140, the stator profile 144, and the stator housing 142 in the vane motor. In some embodiments, the positive displacement motor is elastomer-free.

[0051] 16 and 17 illustrate an embodiment of the drilling system 20 in which the drive mechanism 24 includes a turbine motor. The turbine motor may include a housing 147 containing a plurality of rotor blades 148 distributed around a central shaft 149. The rotor blades 148 are configured to rotate to rotate the central shaft 149 in the direction of the arrow in FIG. 17. The turbine motor uses the drilling media flowing through the implement to rotate the central shaft 149 (i.e., convert hydraulic or pneumatic horsepower to mechanical horsepower). In the filter mode, at least a portion of any solids contained in the drilling media flowing through the separation device 22 are filtered out as the drilling media flows through the space between the rotor blades 148 and the housing 147 within the turbine motor, such that the drilling media contains a smaller amount or volume of solids and smaller-sized solids, thus reducing the risk of damage or failure of the turbine motor.

[0052] 18 and 19 illustrate an embodiment of the drilling system 20 in which the drive mechanism 24 includes a friction-reducing tool. The friction-reducing tool may include a rotor 150 disposed within a stator 152. A valve 154 may be affixed to the downstream end of the rotor 150. The valve 154 includes a flow path 156 that is open to a flow path 158 in a steady valve 160 in the open valve position shown in FIG. 18. The flow path 156 is closed in the closed valve position shown in FIG. 19. In the closed valve position, drilling medium is blocked from flowing into the flow path 158 of the steady valve 160. In other words, the friction-reducing tool uses the drilling medium flowing through the tool to rotate the rotor 150 (i.e., convert hydraulic or pneumatic horsepower into mechanical horsepower), which transitions the valve 154 between the open valve position and the closed valve position. In the filter mode, at least a portion of any solids contained in the drilling media flowing through the separation device 22 are filtered out so that the drilling media contains a smaller amount or volume of solids and smaller sized solids as it flows between the rotor 150 and stator 152 within the friction reduction equipment, thus reducing the risk of damage or failure of the friction reduction equipment.

[0053] 20 and 21 illustrate an embodiment of the drilling system 20 in which the drive mechanism 24 includes a hammer device. The hammer device may include a housing 162, which may contain a mandrel 164 and one or more pistons 166 slidably disposed in the annular space between the mandrel 164 and the housing 162. A downstream surface of each piston 166 may serve as a hammer surface 168, and an upstream-facing shoulder of the mandrel 164 may serve as an anvil surface 170. The hammer device uses drilling medium flowing through the hammer device to slide the pistons 166 downstream (i.e., convert hydraulic or pneumatic horsepower into mechanical horsepower) until the hammer surface 168 of each piston 166 generates an impact in response to striking the anvil surface 170 of the mandrel 164. In the filter mode, at least a portion of any solids contained in the drilling media flowing through the separation device 22 are filtered out so that the drilling media contains a smaller amount or volume of solids and smaller sized solids as it flows through the hammer device, thus reducing the risk of damage or failure to the turbine motor.

[0054] In each of these embodiments, drive mechanism 24 need not include any elastomeric components or any other high temperature sensitive materials, which allows drive mechanism 24 to operate at temperatures above 320° F. In some embodiments, drive mechanism 24 is configured to operate at temperatures between 320° F. and 1,110° F., or any subrange therein.

[0055] 22 , the drilling system 20 may be secured to the distal end of a coiled tubing string 180 with a coiled tubing connector 182 for use in drilling a wellbore 184 extending below a surface 186 through a subterranean formation 188. 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 crusher 190 positioned downstream. Drilling media may be pumped through the coiled tubing string 180 and the coiled tubing connector 182. As the drilling media flows through the separation device 22 in the filter mode (i.e., the default mode), all or a portion of the solid particles within the drilling media are removed and collected in the separation device 22. The cleaned drilling media (i.e., the remaining liquid or gas components) flows downstream through the drive mechanism 24 and the drill bit 26. In embodiments of the separation device 22 that are activated in response to an automatic trigger, the separation device 22 may be set to the flushing mode when the separation device 22 reaches a predetermined threshold volume or amount of collected solids and the upstream fluid pressure increases by a predetermined amount. In the flushing mode, the separation device 22 uses the flow of drilling media to flush the collected solid particles out of the separation device 22, through the flushing outlet 28, and into the annulus 192 between the drilling system 20 and the formation 188. Once the upstream fluid pressure drops below a predetermined deactivation value, the separation device 22 may automatically switch back to the filter mode such that solid particles are collected from the drilling media flowing through the separation device 22 and the cleaned drilling media then flows through the drive mechanism 24. The separation device 22 may also be set to the filter mode or the flushing mode in response to a signal received from the surface of the wellbore. Such signals may be, but are not limited to, a sequence of pressure pulses (mud gravity change), flow rate changes, drill pipe rotation changes, or the use of RFID (Radio Frequency Identification) technology.

[0056] Referring to FIG. 23 , the drilling system 20 may be affixed to the distal end of the drill string 194 for use in drilling the wellbore 184. In this embodiment, the MWD tool 189 may be positioned upstream of the separation device 22, with the drive mechanism 24 and drill bit 26 positioned downstream. The drive mechanism 24 may include a flex-casing drilling motor. Drilling media flowing through the drill string 194 may flow through the separation device 22 before reaching the drive mechanism 24 and drill bit 26. The separation device 22 in filter mode may remove some or all of the solid particles in the drilling media. In the same manner as in FIG. 22 , when collected solid particles in the separation device 22 cause the upstream fluid pressure to reach a predetermined activation value, the separation device 22 is activated and set to the flushing mode. When activated, the fluid flowing through the separation device 22 flushes the collected solids through the flushing outlet 28 into the annulus 192 between the drilling system 20 and the formation 188. After deactivation, the fluid flowing through the separation device 22 in filter mode is again cleaned before entering the drive mechanism 24 .

[0057] FIG. 24 illustrates an alternative embodiment of the drilling system 20 affixed to the distal end of the drill string 194 for use in drilling a wellbore 184. In this embodiment, the MWD tool 189 may be positioned downstream of both the separation device 22 and the drive mechanism 24. The drilling system 20 may include a steering mechanism 32 disposed between the MWD tool 189 and the drill bit 26. The steering mechanism 32 may be a rotary steerable system. In this embodiment, the separation device 22 in filter mode removes all or a portion of the solid particles from the drilling media before the drilling media reaches the drive mechanism 24. The separation device 22 is activated to a washout mode once a predetermined amount of solids has been collected. In the washout mode, fluid washes the collected solids through the washout outlet 28 into the annulus 192 between the drilling system 20 and the subsurface formation 188. The separation device 22 is then deactivated and set to the filter mode, where it again removes and collects solid particles from the drilling media.

[0058] Alternatively, the separation device 22 used as illustrated in Figures 22-24 may be activated and switched to flushing mode in response to a signal from the surface. For example, the signal may be a pressure pulse, an electrical signal, a magnetic signal, a mechanical signal (rotational speed change, weight-on-bit (WOB) change, axial movement of the drill pipe, etc.), or any other type of signal that can be detected within the wellbore 184.

[0059] As shown in FIG. 25 , two or more drilling systems 20 may be used within a drill string 194 when drilling a wellbore 184. An upstream drilling system 20A may be secured to the downstream end of the drill string 194, and a tubular string 196 may be secured 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 may be configured to drive the drill bit 190, while the drive mechanism 24A may be configured to generate vibrations, activate a valve or any actuation device, or power a generator. For example, the drive mechanism 24B may include a positive displacement motor (e.g., a vane motor or Moyno motor), a turbine, a percussion motor, or a hammer, while the drive mechanism 24A may include a turbine, a friction-reducing tool, or a vibration-generating tool.

[0060] 26-29 illustrate the interaction of the modes of downstream separation device 22B relative to the modes of upstream separation device 22A. In the illustrated embodiment, separation device 22A and separation device 22B both include the same features and functionality described above in connection with filter 86. In some embodiments, separation device 22A and separation device 22B are configured to be independently activated from filter mode to flush 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 separation device 22A may be configured to respond to surface signals A and C, while separation device 22B may be configured to respond to surface signals B and C. In this manner, a surface signal can activate separation device 22A only, separation device 22B only, or both separation device 22A and separation device 22B. In other embodiments, separation device 22A and separation device 22B are all configured to be simultaneously activated in response to the same automatic activation trigger and / or the same signal from the surface of the wellbore.

[0061] 25 and 26, both separation device 22A and separation device 22B are illustrated in filter mode. In this mode, the drilling media flows through the filter flow path in the upstream separation device 22A, i.e., through fluid passage 98A, through the openings in the filter surface 92A, through the lower port 118A, and to the drive mechanism 24A. A portion of the solids from the drilling media collected by the separation device 22A are retained so that the solids content and size of the drilling media are reduced before entering the drive mechanism 24A. After flowing through the drive mechanism 24A, the drilling media flows through the tubular string 196 and the MWD device 189 and then enters the downstream separation device 22B. In the illustrated filter mode, the drilling media flows through the filter flow path in the downstream separation device 22B, i.e., through fluid passage 98B, through the openings in the filter surface 92B, through the lower port 118B, and to the drive mechanism 24B. A portion of the solids from the drilling media that are collected by separation device 22B are retained so that the solids content and size of the drilling media is reduced before entering drive mechanism 24B. After flowing through drive mechanism 24B, the drilling media flows to the drill bit 190.

[0062] 25 and 27, the upstream separation device 22A can be activated alone to flush collected solids out of the upstream separation device 22A and into the annulus 192. In the illustrated full flush mode of the separation device 22A, no appreciable amount of drilling medium flows to the downstream separation device 22B. Instead, substantially all of the drilling medium flowing into the upstream separation device 22A flows through the flush flowpath of the upstream separation device 22A, i.e., through the upper port 116A, the opening in the filter surface 92A, the fluid passage 98A, and exits the separation device 22A through the flush outlet 28A. In this mode, the drilling medium flushes collected solids out of the separation device 22A and into the annulus 192. No drilling medium flows downstream past the separation device 22A when the separation device 22A is in the full flush mode. The mode of the downstream separation device 22B does not affect the drilling media flow when the upper separation device 22A is in this mode.

[0063] 25 and 28, the downstream separation device 22B can be activated to a full flushing mode while the upstream separation device 22A remains in a filter mode to flush and purify only the downstream separation device 22B. Drilling media entering the upstream separation device 22A flows through the filter flow path to the upstream drive mechanism 24A. After flowing through the tubular string 196 and the MWD 189, the drilling media enters the downstream separation device 22B. Substantially all of the drilling media flows through the flushing flow path of the separation device 22B, i.e., through the upper port 116B, the opening in the filter surface 92B, the fluid passage 98B, and exits the separation device 22B through the flushing outlet 28B.

[0064] 25 and 29, both separation device 22A and separation device 22B can be activated in flushing mode simultaneously. For example, upper separation device 22A can be set to partial flushing mode, in which a portion of the drilling medium entering separation device 22A flows through the flushing channels of separation device 22A and flushes collected solids out through flushing outlet 28A into annulus 192. The remainder of the drilling medium entering separation device 22A flows through the filter channels of separation device 22A, through upstream drive mechanism 24A, through tubular string 196, through MWD 189, and enters downstream separation device 22B. In the embodiment illustrated in FIG. 29, downstream separation device 22B is activated in full flushing mode, such that substantially all of the drilling medium entering separation device 22B flows through the flushing channels of separation device 22B and exits through flushing outlet 28B into annulus 192. Alternatively, the downstream separation device 22B may be set in a partial flush mode while the upstream separation device 22A is in a partial flush mode so that a portion of the drilling medium flows to the downstream drive mechanism 24B and the drill bit 190.

[0065] As used herein, "driving mechanism" means any device or implement capable of converting hydraulic or pneumatic horsepower into mechanical horsepower (such as, but not limited to, mechanical horsepower for use in driving a bit or grinder, powering an electrical generator, activating a valve, activating any actuating device, or generating vibration or impact).

[0066] As used herein, "elastomer" means any material that has elastic material properties (such as, but not limited to, polymers that are capable of recovering their original shape after being stretched, contracted, expanded, or distorted).

[0067] As used herein, "elastomer-free" in reference to a mechanism or device means a mechanism or device that does not have any components formed from any elastomer.

[0068] As used herein, "high temperature sensitive material" means a material that degrades, decomposes, melts, or undergoes a change in at least one mechanical property at temperatures above 320°F, or at temperatures between 320°F and 1,110°F, or any subrange therebetween, to such an extent that the material becomes unusable in a drilling system.

[0069] As used herein, "drilling media" means any liquid or compressible gas that may contain solid particles.

[0070] Unless otherwise described or illustrated, each of the components within the device 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 a wear-resistant material such as tungsten carbide, ceramic, or ceramic-coated steel.

[0071] Each device described in this disclosure may include any combination of the described components, features, and / or functions of each individual device embodiment. Each method described in this disclosure may include any combination of the described steps in any order, and may include the absence of certain described steps and combinations of steps used in separate embodiments. Any range of numerical values ​​disclosed herein includes any subranges therein. "Plurality" means "two or more." "Above" and "below" shall be interpreted to mean "upstream" and "downstream," respectively, such that the directional orientation of the device is not limited to a vertical arrangement.

[0072] While preferred embodiments have been described, it is to be understood that the embodiments are illustrative only, and that the scope of the invention is intended to be defined solely by the appended claims, when given their full range of equivalents, and that many variations and modifications will naturally occur to those skilled in the art from a review of this specification.

Claims

1. 1. A drilling system for use in drilling a well, comprising: A drive mechanism; a separation device disposed upstream of the drive mechanism, the separation device including a filter flow path and a wash flow path, the wash flow path extending to a wash outlet on an outer surface of the separation device; Equipped with 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 the separation device is configured to flush at least a portion of the filtered solids through the flushing outlet and over the outer surface of the separation device as the drilling medium flows through the flushing flow path. Drilling system.

2. 2. The drilling system of claim 1, wherein the separation device is configured to direct the drilling medium through the filter flow path in a filter mode, and activation of the separation device sets the separation device to a flushing mode, and 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 of claim 2 , wherein the isolation device is activated in response to a signal from the surface of the wellbore.

4. The excavation system of claim 2 , wherein the isolation device is automatically activated in response to an automatic trigger.

5. The drilling system of claim 2 , wherein in the flushing mode, the separation device prevents all of the drilling medium from flowing to the drive mechanism.

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

7. 10. The drilling system of claim 1, wherein the filter flow path extends from a dirty side of the filter surface to a clean side of the filter surface, and the wash flow path extends from the clean side of the filter surface to the dirty side of the filter surface.

8. The drilling system of claim 1 , wherein the drive mechanism includes a positive displacement motor.

9. The drilling system of claim 8 , wherein the positive displacement motor is a Moyno motor or a vane motor.

10. The drilling system of claim 1 , wherein the drive mechanism includes a turbine.

11. The drilling system of claim 1 , wherein the drive mechanism includes a hammer device or a vibration generating device.

12. The drilling system of claim 1 , wherein the drive mechanism includes a friction reducing implement.

13. The drilling system of claim 1 , wherein the drive mechanism includes a steerable drill motor including a flexure.

14. The drilling system of claim 1 , wherein the drive mechanism includes a rotary steerable system.

15. The drilling system of claim 1 , wherein neither the drive mechanism nor the separation device includes any high temperature sensitive materials.

16. a second drive mechanism; a second separation device disposed upstream of the second drive mechanism, the second separation device including a filter flow path and a wash flow path, the wash flow path extending to a wash outlet on an outer surface of the second separation device; Furthermore, the second separation device is configured to filter at least a portion of any solids from the drilling media flowing through the filter flow path; the second separation device is configured to flush at least a portion of the filtered solids through the flushing outlet and over the outer surface of the second separation device when the drilling medium flows through the flushing channel; The drilling system of claim 1 .

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

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

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

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

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

22. 1. A method of drilling a well, comprising: a) providing a drilling system, the drilling system comprising: a drive mechanism; and a separation device disposed upstream of the drive mechanism, the separation device including a filter flow path and a wash flow path, the wash flow path extending to a wash outlet on an outer surface of the separation device; b) drilling a wellbore in a subterranean formation using the drilling system; c) flowing the drilling medium through the filter flow path of the separation device to filter at least a portion of any solids in the drilling medium, wherein any filtered solids are retained within the separation device; d) flowing the drilling medium to the drive mechanism; e) activating the separation device, causing the drilling medium to flow through the washout channels of the separation device and washing at least a portion of the filtered solids through the washout channels and through the washout outlet into an annulus between the outer surface of the separation device and the wellbore; A method comprising:

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

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

25. 23. The method of claim 22, further comprising: f) deactivating the separation device and flowing drilling fluid through the filter flow path, wherein steps (b)-(e) are performed without removing the separation device from the wellbore.

26. 23. The method of claim 22, wherein neither the drive mechanism nor the separation device includes any high temperature sensitive materials.

27. In step (a), the drilling system further includes a second drive mechanism and a second separation device disposed upstream of the second drive mechanism, the second separation device including a filter flow path and a wash flow path, the wash flow path extending to a wash outlet on an outer surface of the second separation device, the second drive mechanism and the second separation device being disposed downstream of the drive mechanism, and the method further includes: 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; h) activating the second separation device, causing the drilling medium to flow through the wash channels of the second separation device and washing at least a portion of the filtered solids through the wash channels and through the wash outlet into the annulus; 23. The method of claim 22, comprising:

28. 28. The method of claim 27, wherein steps (e) and (h) occur simultaneously or sequentially.

29. 28. The method of claim 27, wherein steps (e) and (h) occur independently.

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