Downhole Mud Filter with Magnetic Debris Capture
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Solution Overview
Problem
Current methods for removing debris from drilling fluid in oil and gas operations often fail to ensure that sensitive BHA tools and components are protected from micronized metallic and magnetized debris, leading to potential damage and survey errors.
Innovation Solution
A downhole mud filtration tool with a tubular body, cylindrical screen/mesh, and optional magnetic assembly, burst/rupture disc, and bristle ring, designed to capture and divert debris-laden fluid away from the bore, ensuring that only clean fluid enters sensitive tools, with features like varying opening sizes and materials for different debris tolerance and viscosities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If shale shakers with vibrating fine screens are used to remove solids from drilling fluid, then large drill solids and cuttings are removed, but fine steel filings are not captured
Solution Approach 1:
The invention divides the debris removal process into two stages: first using shale shakers to remove large solids, then using a magnetic assembly in the drill string to capture fine metallic filings. This segmentation of the filtration system allows each component to target specific debris sizes, resolving the contradiction between removing large solids and capturing fine particles.
Solution Approach 2:
The magnetic assembly acts as an intermediary component within the drill string that specifically targets fine metallic filings which pass through the shale shaker screens. By placing magnets inside the drill string, the system captures debris that the primary surface equipment misses, thereby protecting sensitive BHA tools while maintaining the effectiveness of the existing shale shaker system.
2Reliability
If ditch magnets are used to capture fine metallic particles, then metallic debris is removed from fluid, but debris can be washed off magnets and pass through shale shaker screens
Solution Approach 1:
The magnetic assembly is positioned upstream within the drill string, before the fluid returns to the surface through the annulus. This preliminary capture of metallic debris inside the pressurized drill string prevents the debris from being washed off by surface equipment and ensures that only clean fluid enters the wellbore, eliminating the washout problem associated with ditch magnets.
3Reliability
If a magnetic assembly is mounted inside the drill string, then ferrous debris is captured, but the tool complexity increases
Solution Approach 1:
The magnetic assembly is integrated into the existing drill string structure, allowing it to serve multiple functions: capturing metallic debris, protecting sensitive BHA tools, and maintaining drill string integrity. By making the system multi-functional and integrating it into existing infrastructure, the complexity increase is minimized while achieving comprehensive debris protection.
4Reliability
If screen mesh with small openings is used to capture fine debris, then debris capture improves, but fluid flow restriction increases
Solution Approach 1:
The invention replaces the mechanical filtration system (screen mesh with small openings that restrict flow) with a magnetic field-based system. The magnetic assembly captures fine metallic filings without physically blocking the fluid flow path, thereby maintaining high fluid flow rates while achieving effective debris capture. This substitution of mechanical filtration with magnetic separation resolves the contradiction between debris capture and fluid flow.
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
Effectively captures and removes debris from drilling fluid, preventing damage to sensitive BHA tools and components, while maintaining flow rates and preventing debris washout, ensuring the fluid entering the drill string is clean and free from metallic particles.
Implementation Method 1
High strength magnets mounted along a tool body attracts any ferrous debris present in the drilling fluid in the wellbore
Implementation Method 2
a mesh-like or slotted screen where the debris-laden fluid in the wellbore can enter annular gap between the screen and mandrel but the mesh/slots capture and prevent debris from escaping back into the wellbore
Data Source
AI summary
A downhole mud filter (100) comprising a tubular member (1) connectable to the drill string used to prevent debris-laden fluid from entering sensitive BHA tools and components further downhole relative to the mud filter. A tubular member having a sub assembly consisting of a bristle rings (6) and/or rupture (7) to intentionally create a restriction and divert debris-laden fluid around a cylindrical mesh (2) and/or screen surrounded by permanent magnets (3). The openings (9) on the mesh and/or screen allow fluid to pass through while preventing particulates or debris from entering and retaining such debris on the outside of the screen and/or mesh. Magnets (3) arranged around the outer diameter of the screen and/or mesh (2) and along its length captures and retains smaller ferrous debris which the screen and/or mesh cannot filter.