Electromagnetic Debris Removal in Drilling Fluids
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Solution Overview
Problem
Magnetic debris in drilling fluids can restrict and damage bottom hole assemblies (BHA) during drilling operations, reducing efficiency and potentially making them inoperable due to the failure of existing technologies to effectively remove these debris before they reach sensitive components.
Innovation Solution
An internal assembly within a tool that includes an electromagnet and a sleeve, configured to attract and accumulate magnetic debris from the drilling fluid, allowing filtered fluid to flow through while the electromagnet is on, and flushing accumulated debris when it is off, preventing damage to the BHA.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic debris is removed from drilling fluid using existing technologies, then BHA damage is prevented, but the system complexity increases and filtering efficiency is insufficient
Solution Approach 1:
The filtering system is divided into multiple electromagnetic elements (permanent magnets and/or electromagnets) arranged in a segmented pattern around the annulus. Each magnetic element creates a localized magnetic field that collectively captures magnetic debris throughout the fluid flow path, distributing the filtering function across multiple simple components rather than one complex filter
Solution Approach 2:
The patent replaces mechanical filtering systems (such as physical filters or screens that require backflushing and maintenance) with an electromagnetic field-based debris capture system. The magnetic elements attract and hold magnetic debris through magnetic force, eliminating the need for complex mechanical filtering mechanisms while maintaining reliable BHA protection
2Productivity
If magnetic debris accumulates in the annulus for continuous filtering, then filtering efficiency improves, but pressure loss increases
Solution Approach 1:
The system periodically reverses the polarity of the electromagnetic elements or activates/deactivates them in sequence, creating alternating magnetic fields that prevent debris from forming a continuous restrictive layer in the annulus. This periodic action maintains high filtering efficiency by constantly redistributing captured debris while minimizing pressure loss through the flow path
Solution Approach 2:
The electromagnetic elements are configured to dynamically change their magnetic field strength or polarity based on operating conditions. By adjusting the magnetic field characteristics in real-time, the system optimizes debris capture efficiency while preventing excessive pressure buildup that would occur with static magnetic fields, thus balancing productivity and energy loss
3Reliability
If electromagnet remains on to continuously attract debris, then debris removal effectiveness improves, but energy consumption increases
Solution Approach 1:
The electromagnet operates in periodic cycles, alternating between on and off states, rather than remaining continuously on. During the on state, magnetic debris is attracted and captured; during the off state, the system reduces energy consumption. This periodic operation maintains effective debris removal while significantly reducing overall energy usage compared to continuous operation
Solution Approach 2:
The system changes the operational parameters of the electromagnet, specifically the duty cycle (ratio of on-time to total cycle time) and magnetic field strength, to optimize the balance between debris removal effectiveness and energy consumption. By adjusting these parameters based on drilling conditions, the system achieves reliable debris removal with minimized energy expenditure
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 solution effectively prevents magnetic debris from reaching and damaging the BHA, maintaining drilling efficiency and reducing pressure loss by continuously filtering and flushing out the debris, thereby ensuring the longevity and performance of the drilling system components.
Implementation Method 1
an electromagnet held by the retainer and configured to actuate between an on state and an off state... When the electromagnet is in the on state, the electromagnet is configured to attract magnetic debris in the drilling fluid
Data Source
AI summary
An internal assembly (230) for a tool (200) includes a retainer (232) that at least partially defines an axial bore (238). The retainer (232) further defines a port (246) providing a path of fluid communication from an exterior of the retainer to the bore (238). The internal assembly (230) also includes an electromagnet (250) coupled to the retainer (232). The electromagnet (250) is configured to actuate between an on state and an off state and to attract magnetic debris in a fluid when in the on state. The internal assembly (230) also includes a sleeve (260) that is configured to be positioned downstream from the retainer (232). The sleeve (260) at least partially defines the bore (238). The sleeve (260) further defines a port (262) that provides a path of fluid communication from the bore (238) to an exterior of the sleeve (260). The internal assembly (230) also includes a valve (270) configured to be positioned downstream from the port (262) in the sleeve (260).