Self-Flushing Debris Catcher and Choke for Automatic Drill-Out
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Solution Overview
Problem
Conventional well operation fluid treatment systems require manual intervention and additional equipment for debris removal, posing health, safety, and environmental risks, and increasing rig-up time.
Innovation Solution
A self-cleaning debris catcher system that utilizes the pressure of the fluid source to automatically switch between debris catching and flushing modes, integrating debris catchers, pressure control, and flushing systems into a single skid, eliminating the need for external pumps and manual operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual debris removal procedures are used (isolating debris catcher, removing cleaning cap, removing screen, physically removing solids), then personnel can remove accumulated solids, but health, safety, and environmental risks increase due to manual intervention in high-pressure systems
Solution Approach 1:
The system uses the well fluid itself to flush and clean the debris catcher, eliminating the need for external pumps and manual intervention. The debris catcher automatically flushes itself using the flowing well fluid, reducing personnel exposure to high-pressure equipment while maintaining effective debris removal capability
Solution Approach 2:
The patent replaces manual mechanical operations (opening/closing valves, removing caps, physically removing debris) with an automated system that uses fluid dynamics and remote-controlled valve actuation. The controller automatically manages the flushing sequence, substituting human mechanical actions with automated control mechanisms
2Ease of repair
If external flush pumps and additional valves are connected to the debris catcher, then accumulated solids can be removed, but device complexity increases
Solution Approach 1:
The debris catcher is designed with multi-functionality, serving both as a debris collection device and a self-flushing system. The same inlet and outlet ports are used for both normal fluid flow and flushing operations, eliminating the need for separate flush pump connections and additional valves
Solution Approach 2:
The patent extracts the flushing function from the main debris catcher body by using a separate, pre-assembled debris catcher assembly that includes integrated flushing capability. This modular design allows the flushing function to be built-in rather than added through external equipment
3Ease of operation
If debris catchers are manually isolated and cleaned, then solids can be removed, but productivity decreases due to time-consuming manual operations
Solution Approach 1:
The system performs preliminary action by automatically flushing the debris catcher during normal operation without requiring shutdown or manual intervention. The controller initiates the flushing sequence when debris accumulation is detected, removing solids before they interfere with system performance
Solution Approach 2:
The patent maintains continuity of useful action by enabling automatic flushing operations that can be performed without shutting down the well flow. The system continuously monitors and cleans the debris catcher, ensuring uninterrupted debris removal capability and maximizing operational productivity
4Reliability
If multiple skids with debris catchers and choke manifolds are positioned at specific distances and connected via pipes, then fluid treatment can be performed, but rig-up time increases
Solution Approach 1:
The patent merges the debris catcher and choke manifold functions into a single integrated assembly or co-located skid, eliminating the need for separate positioning and piping connections between multiple skids. This consolidation reduces rig-up time while maintaining the reliability of fluid treatment operations
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
Reduces rig-up time, minimizes personnel exposure to high-pressure equipment, and enhances safety by automating valve actuation, thereby reducing health, safety, and environmental risks.
Implementation Method 1
a pressurized fluid stream from wellbore operations is received by a debris catcher and choke system
Data Source
Figure 1
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AI summary
An improved debris catcher and choke system for receiving a pressurized fluid stream from wellbore operations where a controller can selectively place a plurality of debris catchers in debris catching or flushing modes, and the cleaned fluids from one of the debris catchers can be used to flush one of the other debris catchers. One or more embodiments relate to systems and methods for utilizing debris catchers and choke valves.