Downhole Debris Catcher Modular Receptacles
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Solution Overview
Problem
Existing downhole debris catching tools face issues with debris plugging passages, limited capacity, and difficulty in removing compacted debris without damaging components, especially when reverse circulation is used in milling operations.
Innovation Solution
A modular debris catching device with undulating flow paths and flapper valves that facilitate debris collection and prevent backflow, along with an offset return path in the mill design to enhance circulation and reduce clogging, allowing for easier disassembly and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reverse circulation is used to capture debris, then debris collection effectiveness is improved, but passage plugging occurs
Solution Approach 1:
The tool is divided into multiple debris receptacles (first and second receptacles) that can be independently filled and emptied. This segmentation allows continuous operation - while one receptacle is being used, another can be emptied, preventing passage plugging and maintaining debris collection effectiveness.
Solution Approach 2:
The debris receptacles are designed to be collapsible or removable, allowing dynamic adjustment of the tool's internal configuration. This enables easy emptying of debris without damaging components, resolving the plugging issue while maintaining collection effectiveness.
2Quantity of substance
If tube length is increased to expand annular space capacity, then debris holding capacity is improved, but tube structural integrity deteriorates
Solution Approach 1:
Instead of using one long tube, the tool uses multiple shorter debris receptacles stacked vertically. Each receptacle maintains adequate structural integrity while the collective arrangement provides sufficient debris holding capacity for the entire tool assembly.
3Ease of manufacture
If threaded connection is used to assemble tool components, then ease of assembly is improved, but component damage occurs during debris removal
Solution Approach 1:
The debris receptacles are designed with collapsible or removable features that allow easy disassembly and emptying without requiring forceful manipulation that could damage threaded connections or other components.
Solution Approach 2:
The debris receptacles can be independently removed from the tool assembly, allowing debris to be emptied separately without disassembling the entire tool or risking damage to permanently attached components like threaded connections.
4Quantity of substance
If screen is used to filter debris, then fluid separation is improved, but debris falls through when circulation stops
Solution Approach 1:
Flapper valves provide dynamic control of debris flow paths. When circulation is active, valves open to allow fluid passage; when circulation stops, valves automatically close to prevent debris from falling through screens, maintaining both separation efficiency and containment reliability.
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
The modular design effectively captures debris, reduces clogging, and simplifies the removal and reassembly of the tool, ensuring efficient milling performance and minimizing damage to components.
Implementation Method 1
modular debris receptacles that are held in the housing in a manner that facilitates stacking and a generally undulating flow path to facilitate dropping of the debris into the receptacles
Implementation Method 2
Another design involves establishing a reverse circulation with jets that discharge outside a tool body toward a mill below and act as eductors to draw fluids through the mill and into a screened section central passage
Implementation Method 3
jets that discharge outside a tool body toward a mill below and act as eductors
Implementation Method 4
Once the debris laden fluid exits the central passage the velocity slows and debris drops into an annular passage
Data Source
AI summary
A debris catching device for downhole milling features modular debris receptacles that are held in the housing in a manner that facilitates stacking and a generally undulating flow path to facilitate dropping of the debris into the receptacles as the remaining fluid travels up the tool for ultimate screening before the fluid exits the tool to flow up to the surface or in a reverse circulation pattern back to the mill below the debris catcher. The modules can also be aligned with flapper valves at the top of each module to prevent debris in the tool from falling to the mill if circulation is turned off. The mill is configured to have an off-center return path preferably as large as the passage through the mill body to aid circulation and cutting performance.