Patent Application
20240175350
This disclosure relates to downhole filtration systems for use in drill strings, such as a smart downhole filtration system that monitors plugging of a downhole filtration system in real time.
Filter subs are utilized during drilling operations to prevent debris from entering various downhole tools along a drill string. However, filter subs may become plugged with debris and accordingly become inefficient. There is no technology available that indicates whether a filter sub has become plugged with debris to alert personnel of the need for mud cleaning or improved solids control efficiency.
This disclosure relates to a downhole filtration system for use in a drill string, such as a smart downhole filtration system that automatically monitors plugging of the system in real time to assess system performance.
In one aspect, a downhole filtration system for use in a drill string includes a filter assembly configured to filter debris from a drilling fluid, a first pressure sensor located at an uphole end of the filter assembly, a second pressure sensor located at a downhole end of the filter assembly, and a control unit configured to receive and transmit data from the first and second pressure sensors to surface equipment in real time.
Embodiments may provide one or more of the following features.
In some embodiments, the downhole filtration system is configured to allow through-flow of the drilling fluid.
In some embodiments, the downhole filtration system is configured to detect a difference in pressure between the uphole end and the downhole end.
In some embodiments, the difference in pressure indicates plugging of the filter assembly.
In some embodiments, the control unit includes one or more receivers.
In some embodiments, the one or more receivers are configured to receive the data from the first and second pressure sensors in real time.
In some embodiments, the one or more receivers are configured to receive remote commands from the surface equipment in real time.
In some embodiments, the remote commands include an activation signal.
In some embodiments, the remote commands include a deactivation signal.
In some embodiments, the control unit is configured to receive and transmit data wirelessly.
In some embodiments, the control unit includes one or more transmitters.
In some embodiments, the one or more transmitters are configured to transmit the data from the first and second pressure sensors to the surface equipment in real time.
In another aspect, a method of filtering a drilling fluid includes passing the drilling fluid through a filter assembly of a downhole filtration system, detecting an uphole pressure at a first pressure sensor located at an uphole end of the filter assembly, detecting a downhole pressure at a second pressure sensor located at a downhole end of the filter assembly, and transmitting data including the uphole and downhole pressures from a control unit of the downhole filtration system to surface equipment in real time.
Embodiments may provide one or more of the following features.
In some embodiments, the method further includes determining a difference between the uphole and downhole pressures.
In some embodiments, the method further includes preventing plugging of one or more components of a drill string positioned downhole of the downhole filtration system.
The details of one or more embodiments are set forth in the accompanying drawings and description. Other features, aspects, and advantages of the embodiments will become apparent from the description, drawings, and claims.
The downhole filtration system 100 is a smart, automated system that acquires equipment diagnostic data and transmits the data to the surface 115 (e.g., equipment located at the surface 115) in real time. Referring to
The pressure sensors 104, 108 are located within an interior region 114 of the filter assembly 102. The pressure sensors 104, 108 are operable to detect internal pressures respectively above and below the downhole filtration system 100 in real time. Detection of a substantial difference in pressure between the uphole and downhole ends 106, 110 of the filter assembly 102 indicate an extent to which the downhole filtration system 100 is plugged with debris. In some examples, a pressure difference of about 344,738 Pa (about 50 psi) or greater indicates that action should be taken to address debris plugging.
The control unit 112 provides an interface between the filter assembly 102 and the surface 115. The control unit 112 includes one or more receivers 116 that receive data (e.g., pressure measurements and other measurements) from the pressure sensors 104, 108. The one more receivers 116 also receive data (e.g., remote commands) from the surface 115. In some examples, commands received from the surface 115 cause or allow the downhole filtration system 100 to functionally activate or deactivate (e.g., for an unlimited number of times). The control unit 112 further includes one or more transmitters 118 that transmit data received from the pressure sensors 104, 108 to the surface 115 and that transmit data received from the surface 115 to the pressure sensors 104, 108 or other components of the filter assembly 102. In some embodiments, the one or more receivers 116 and the one or more transmitters 118 may be designed to receive and send commands and other data wirelessly (e.g., illustrated as a wireless signal 120), electromagnetically, or in a wired manner.
The control unit 112 and the pressure sensors 104, 108 together form a closed-loop communication system that delivers a full diagnostic analysis of the downhole filtration system 100 to the surface 115 in real-time. In this way, the control system 112 manages information between the surface 115 and the downhole filtration system 100. On the whole, the downhole filtration system 100 addresses the need to improve verification of debris accumulation inside of filter subs that are utilized during drilling and workover operations in oil and gas wells. For example, the automated features of the downhole filtration system 100 provides an improved efficiency of drilling and workover operations as compared to that provided by conventional filter subs.
The downhole filtration system 100 provides an early indication that debris has been encountered in the filter assembly 102 so that immediate action can be taken to improve cleaning of the drilling fluid 111 (e.g. to improve mud cleaning or solids control efficiency). Such action may prevent or delay the need to remove (e.g., pull out) the filtration system 100 from the wellbore 113 to clean the filter assembly 102. Similarly, such action may prevent damage to various components of the drill string 101 below the downhole filtration system 100 and thus eliminate the need to perform multiple, undesired trips to change out or clean the downhole filtration system 100. Accordingly, use of the downhole filtration system 100 minimizes non-productive time at wellbore 113 and accordingly provides a significant yearly cost savings.
While the downhole filtration system 100 has been described and illustrated with respect to certain dimensions, sizes, shapes, arrangements, materials, and methods, in some embodiments, a downhole filtration system that is otherwise substantially similar in construction and function to the downhole filtration system 100 may include one or more different dimensions, sizes, shapes, arrangements, configurations, and materials or may be utilized according to different methods. Accordingly, other embodiments are also within the scope of the following claims.
