Multi-Basket Junk Recovery Tool with Integrated Sensors

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Solution Overview

Problem

Conventional junk recovery tools are inefficient in collecting debris from drilling fluids and often require tripping out of the wellbore to monitor their status, leading to potential issues like stuck pipes and reservoir damage.

Innovation Solution

A junk recovery tool featuring a longitudinal axial mandrel with multiple junk recovery baskets of varying aperture sizes, integrated with sensors to measure and filter debris, allowing continuous operation until full and preventing guesswork about tool status.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional junk recovery tools are used, then the structure is simple, but the junk collection efficiency is low and frequent tripping is required

Engineering Contradiction:

Improvejunk collection efficiencyVSAvoidtool structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The junk recovery tool is divided into multiple baskets (e.g., three baskets) with different aperture sizes arranged in sequence. Each basket captures a specific size range of junk, allowing the tool to collect various types of debris simultaneously without requiring frequent tripping, thus improving productivity while maintaining manageable complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each basket is designed with specific aperture sizes tailored to capture particular junk sizes. The first basket has larger apertures for bigger debris, while subsequent baskets have progressively smaller apertures for finer particles. This localized optimization of aperture characteristics enhances overall collection efficiency

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If single aperture size baskets are used, then the manufacturing is simple, but the junk collection coverage is limited

Engineering Contradiction:

Improvejunk size range coverageVSAvoidbasket manufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The filtering function is segmented across multiple baskets, each with a specific aperture size range. This segmentation allows the system to handle a broad spectrum of junk sizes from large debris to fine particles, significantly expanding the adaptability of the tool

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The aperture size parameter is varied across different baskets to optimize junk collection for different size ranges. By changing this critical parameter, the tool achieves versatile junk size coverage while maintaining relatively simple manufacturing for each individual basket

Inventive Principle:

Principle #35Parameter changes

3Loss of information

If no sensors are integrated, then the device complexity is low, but the monitoring capability is insufficient requiring frequent tripping

Engineering Contradiction:

Improvejunk collection status informationVSAvoidsensor integration complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

Junk recovery sensors are integrated into the baskets to provide real-time feedback on junk collection status. The sensors detect when baskets are filling up and transmit this information to the surface, enabling continuous monitoring without frequent tripping and reducing information loss about tool status

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The tool performs self-monitoring through integrated sensors that automatically detect and report junk collection status. This self-service capability eliminates the need for frequent manual inspection and tripping, as the tool independently tracks its own operational state

Inventive Principle:

Principle #25Self-service

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 tool effectively filters and measures debris, ensuring efficient junk collection and preventing wellbore issues by continuously operating until full, reducing the need for frequent removal and monitoring.

Implementation Method 1

Each of the junk recovery baskets may include a plurality of apertures to allow a drilling fluid to pass through the junk recovery basket while collecting junk from the drilling fluid

Methodology Applied

Scientific EffectFluid flow through apertures: Filter (physical)

Implementation Method 2

The at least one junk recovery sensor may be operable to measure an amount of collected junk in the one of the plurality of junk recovery baskets

Methodology Applied

Scientific EffectWeight measurement:

Data Source

PatentUS11555368B2Junk recovery tools and systems and methods of collecting junk

Publication Date: 2023.01.17 SAUDI ARABIAN OIL CO

AI summary

A junk recovery tool may include a longitudinal axial mandrel, a plurality of junk recovery baskets, and at least one junk recovery sensor. The plurality of junk recovery baskets may be spaced apart and attached to the longitudinal axial mandrel. A first one of the junk recovery baskets may be disposed uphole of a second one of the junk recovery baskets. Each of the junk recovery baskets may include a plurality of apertures, allowing a drilling fluid to pass through the junk recovery basket while collecting junk from the drilling fluid. The at least one junk recovery sensor may be disposed in one of the plurality of junk recovery baskets. The at least one junk recovery sensor may be operable to measure an amount of collected junk in the one of the plurality of junk recovery baskets. The present disclosure also includes systems and methods incorporating the junk recovery tool.