Automatic Drill-Out Debris Catcher With Self-Cleaning Pressure Flow
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Solution Overview
Problem
Conventional well operation fluid treatment systems require manual intervention and additional equipment for debris removal from debris catchers, posing health, safety, and environmental risks, and increasing rig-up time.
Innovation Solution
A self-cleaning debris catcher system that utilizes the pressure from the fluid source to automatically switch between debris catching and cleaning modes, integrating debris catchers, pressure control, and flushing systems into a single skid, eliminating the need for manual intervention and external pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual debris removal methods are used (isolating debris catcher, removing cleaning cap, manually removing solids), then debris can be removed from the debris catcher, but personnel exposure to high-pressure equipment increases and rig-up time increases
Solution Approach 1:
The system uses the well fluid itself to flush and clean the debris catcher, eliminating the need for external pumps and manual intervention. The debris catcher automatically flushes itself using the flowing well fluid, reducing personnel exposure and simplifying operations.
Solution Approach 2:
A dual-debris-catcher system is implemented where one debris catcher serves as an intermediary to receive and process debris from the other. This allows continuous operation and automated debris removal without personnel needing to manually handle high-pressure equipment.
2Productivity
If external flush pumps are connected to the debris catcher to pump flushing fluid, then accumulated solids/debris can be removed, but additional equipment and rig-up time are required
Solution Approach 1:
The well fluid serves as the flushing medium, eliminating the need for external pumps. The system uses its own operational fluid to clean the debris catcher, reducing equipment complexity while maintaining debris removal efficiency.
Solution Approach 2:
The well fluid performs multiple functions: it carries debris from the wellbore and simultaneously serves as the flushing medium for cleaning the debris catcher. This multi-functionality eliminates the need for separate flushing equipment.
3Reliability
If separate skids with interconnecting pipelines are used for debris catcher and choke manifold, then proper positioning and connection are achieved, but rig-up time and system complexity increase
Solution Approach 1:
The debris catcher and choke manifold are integrated into a single modular unit, eliminating the need for separate skids and interconnecting pipelines. This reduces rig-up time while maintaining proper positioning and connection through integrated design.
4Ease of operation
If manual valve operations are performed during debris removal, then flow isolation and debris removal can be accomplished, but personnel exposure to high-pressure equipment increases
Solution Approach 1:
The system automatically manages valve operations and debris removal using the flowing well fluid, eliminating the need for manual valve handling. This reduces personnel exposure to high-pressure equipment while maintaining proper flow control.
Solution Approach 2:
Manual mechanical valve operations are replaced with an automated system that uses well fluid flow to control the debris removal process, reducing the need for personnel to physically operate valves in high-pressure environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces rig-up time, minimizes personnel exposure to high-pressure equipment, and enhances safety by automating valve operations, ensuring efficient debris removal without additional equipment.
Implementation Method 1
uses the pressure from the fluid source being cleaned to both: (i) catch debris using the debris catcher(s) in the debris catching mode and (ii) clean/flush the debris catcher(s) in the cleaning/flushing mode
Implementation Method 2
passes through a screen (allowing fluid to pass through but blocking at least a portion of debris and/or solids contained in the fluid)
Implementation Method 3
fluid enters the debris catcher via the inlet and exits via first outlet while carrying accumulated solids and debris with the fluid
Data Source
AI summary
An improved debris catcher and choke system for receiving a pressurized fluid stream from wellbore operations where a controller can selectively place a plurality of debris catchers in debris catching or flushing modes, and the cleaned fluids from one of the debris catchers can be used to flush one of the other debris catchers. One or more embodiments relate to systems and methods for utilizing debris catchers and choke valves.