Modular Downhole Debris Removal Apparatus with Venturi Circulation

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Solution Overview

Problem

Existing downhole debris removal tools face challenges in efficiently collecting and separating debris from circulating fluid in wellbores, often requiring complex assemblies and handling subs, which can be cumbersome and inefficient.

Innovation Solution

A downhole debris removal apparatus featuring a crossover sub with pin and box threads, a debris removal tube with radially extending centralizers, and a surrounding tubular, which allows for modular assembly and efficient debris collection without the need for a handling sub, utilizing a venturi device for fluid circulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If traditional debris collection tools are used, then debris separation function is achieved, but device complexity increases due to requirement of handling subs and complex assemblies

Engineering Contradiction:

Improveassembly complexityVSAvoiddebris collection reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The debris collection tool is divided into modular components: a handle assembly, a debris collection chamber, and a knockout chamber with knockout element. This segmentation allows each component to perform its specific function independently, reducing overall assembly complexity while maintaining reliable debris collection through specialized functional zones.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The knockout chamber and knockout element are extracted as separate removable components from the main debris collection assembly. This extraction allows the knockout mechanism to be independently managed and replaced without affecting the entire assembly, simplifying maintenance and reducing operational complexity while ensuring reliable debris removal.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If traditional debris collection tools are used, then debris collection is achieved, but ease of operation deteriorates due to cumbersome handling subs

Engineering Contradiction:

Improvehandling easeVSAvoiddebris removal efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The handling sub is completely removed from the design. Instead, the tool is operated directly through the handle assembly which interfaces with the wellbore environment, eliminating the cumbersome handling sub while maintaining operational effectiveness and improving ease of use.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Rather than using a complex handling sub to manipulate the tool, the design inverts the approach by making the tool itself self-managing through its handle assembly and removable components, allowing operators to directly control the debris collection and knockout functions without intermediate handling mechanisms.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If complex assemblies with handling subs are used, then debris collection function is achieved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveassembly easeVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The tool is manufactured as discrete modular components (handle assembly, debris collection chamber, knockout chamber) that can be produced separately using optimized processes and then assembled. This segmentation simplifies manufacturing of individual parts while reducing the total number of components needed compared to monolithic traditional designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functions are merged into integrated components: the handle assembly combines handling and operational controls, the debris collection chamber integrates filtration and collection, and the knockout chamber combines debris removal with the knockout element. This merging reduces the total component count and simplifies assembly compared to separate traditional components.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables efficient debris collection and separation with reduced complexity and assembly requirements, improving operational efficiency in well operations by effectively managing debris in wellbores through the described apparatus.

Implementation Method 1

Reverse circulation is generally created by using a tool, sometimes referred to as a venturi device (e.g., power head), to direct flow laden with cuttings and/or particulate material into a debris removal assembly

Methodology Applied

Scientific EffectVenturi effect: Venturi Effect

Data Source

PatentUS11466542B2Downhole debris removal apparatus including a modular knockout chamber

Publication Date: 2022.10.11 HALLIBURTON ENERGY SERVICES INC

AI summary

This disclosure provides a downhole debris removal apparatus, a method for assembling a downhole debris removal apparatus, and a well system including the same. The downhole debris removal apparatus, in one aspect, includes a crossover sub, the crossover sub having a first sub end with one of a sub pin thread or sub box thread, a second sub end with the other of the sub box thread or sub pin thread, and a fluid passageway extending from the first sub end to the second sub end. The downhole debris removal apparatus, according to this aspect, further includes a debris removal tube having a first tube end and a second tube end, the first tube end removably engaged with the crossover sub between the first sub end and the second end.