MAGNETIC METAL EXTRACTOR FROM DRILLING FLUID

Abstract

An exemplary apparatus for removing metallic debris from a drilling fluid is provided that includes a first end member, a second end member, and one or more elongated members extending between the first end member and the second end member. The elongated members may each include at least one magnet. Drilling fluid may flow past the elongated members, which may be located in a drilling fluid cleansing machine such as a shale shaker, so that metallic debris in the drilling fluid, if any exist, are attracted by the magnets in the elongated members. Some of the metallic debris may adhere to an exterior surface of the elongated members so that the metallic debris are removed from the drilling fluid. The metallic debris can then be removed from the exterior surface of the elongated members.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. §119(e), this application claims priority from, and hereby incorporates by reference for all purposes, U.S. Provisional Patent Application Ser. No. 61/914,311, entitled “Magnetic Metal Extractor From Drilling Fluid,” filed Dec. 10, 2013 and naming John W. White as an inventor.

TECHNICAL FIELD

This disclosure relates in general to removing debris from drilling fluid and, in particular, but not by way of limitation, to extracting metal debris from drilling fluid.

BACKGROUND OF THE DISCLOSURE

Drilling fluid, also known as “drilling mud,” is used in oil and gas drilling operations to perform many tasks, such as cooling and lubricating equipment and removing debris from the wellbore. In a drilling operation, drilling fluid is pumped into the wellbore where it collects debris and cools and lubricates equipment, such as the drill head. Then, the drilling fluid is recirculated to the top of the wellbore to carry debris that are suspended in the drilling fluid to the top of the wellbore. The debris that are removed from the wellbore by the drilling fluid may include any type of unwanted material and often include rock and other geological features that have been cut by the drill head, often called “cuttings.”

Drilling fluid may be reused and recirculated to reduce the cost of a drilling operation. The equipment through which the drilling fluid is recirculated, such as, for example, high pressure pumps and drill heads, can be damaged or rapidly worn if the drilling fluid includes residual debris from the wellbore. In order to minimize this type of damage, used drilling fluid is cleaned soon after it is removed from the wellbore and before it enters sensitive equipment. Used drilling fluid is often cleaned using dedicated drilling fluid cleansing equipment, such as shale shakers, by passing the used drilling fluid through one or more screens or other cleansing mechanisms to separate the debris from the drilling fluid. Unfortunately, this equipment often does not remove all debris from the drilling fluid and some debris may remain in the drilling fluid as it is recirculated. For example, small metal debris, such as metal shavings, may enter the drilling fluid as a result of contact between a drill string and the walls of the wellbore while the drill string is rotating or while the drill string is inserted into, or removed from, the wellbore. In the case of horizontal drilling, small metal debris may result if the drill string contacts the walls of the wellbore in the area of curvature of the wellbore as the wellbore transitions from a vertical wellbore to a horizontal wellbore. Metal debris that result from these and other drilling operations are often too small to remove from the drilling fluid using traditional drilling fluid cleansing mechanisms. Unfortunately, these small metal debris can also be very damaging to drilling equipment, such as high pressure pumps, as the used drilling fluid is recirculated.

SUMMARY

In a first aspect, there is provided an apparatus for removing metal debris from a drilling fluid, such as, for example, metal debris that have not been removed by other dedicated drilling fluid cleansing equipment. The apparatus may include a first end member, a second end member and two or more elongated members extending between the first end member and the second end member. The elongated members may each include a magnet.

In some embodiments, the elongated members have a rectangular cross sectional shape, a circular cross sectional shape or a triangular cross sectional shape.

In other embodiments, the first end member and the second end member are cylindrical.

In certain embodiments, the apparatus includes three elongated members.

In some embodiments, the apparatus includes four elongated members.

In another embodiment, the elongated members are equally spaced radially around a central axis of the end members.

In other embodiments, the elongated members have an interior channel and the magnet is located in the interior channel.

In certain embodiments, the interior channel is sealed.

In other embodiments, the interior channel is sealed by the end members that are coupled to ends of the elongated members.

In some embodiments, the interior channel includes a magnet and an adhesive.

In another embodiment, the adhesive includes an epoxy.

In yet another embodiment, the epoxy is an epoxy 50-3185.

In still another embodiment, the interior channel further includes a catalyst.

In certain embodiments, the catalyst is a catalyst number 190.

In other embodiments, each of the elongated members includes a plurality of magnets.

In yet another embodiment, the elongated members include one or more rows of magnets.

In still another embodiment, the elongated members include two rows of magnets.

In certain embodiments, the magnets are a neodymium iron boron magnets.

In other embodiments, a distance between the end members is slightly less than the width of a trough of a drilling fluid cleansing machine.

In a second aspect, there is provided a method of removing metallic debris from a drilling fluid. The method may include flowing at least some of the drilling fluid past a first elongated member to attract at least some of the metallic debris from the drilling fluid to the first elongated member and flowing at least some of the drilling fluid past a second elongated member to attract at least some of the metallic debris to the second elongated member. The first elongated member and the second elongated member may be magnetic.

In certain embodiments, the method includes flowing at least some of the drilling fluid between the first elongated member and the second elongated member.

In other embodiments, the method includes flowing at least some of the drilling fluid past a third elongated member to attract at least some of the metallic debris to the third elongated member.

In another embodiment, the method includes flowing at least some of the drilling fluid between the first elongated member, the second elongated member and the third elongated member.

In yet another embodiment, the method includes locating the first elongated member and the second elongated member in a drilling fluid cleansing machine.

In still another embodiment, the method includes locating the first and second elongated members in a flow path of the drilling fluid in the drilling fluid cleansing machine.

In some embodiments, the method includes locating the first and second elongated members in the flow path of the drilling fluid between a screen and an outlet of the drilling fluid cleansing machine.

In another embodiment, the method includes flowing at least some of the drilling fluid between a first end member and a second end member that are coupled to the first and second elongated members.

In certain embodiments, the method includes contacting at least some of the metallic debris to an exterior surface of the first elongated member or an exterior surface of the second elongated member.

In other embodiments, the method includes removing at least some of the metallic debris from the exterior surface of the first or second elongated members.

In a third aspect, there is provided an apparatus for cleansing drilling fluid that includes an inlet to receive the drilling fluid, a separating mechanism to remove large debris from the drilling fluid and an outlet to expel the cleansed drilling fluid from which at least some of the large debris have been removed. The apparatus may include a flow path of the drilling fluid between the inlet and the outlet that passes through the separation mechanism. A first elongated member and a second elongated member may be located in the flow path and may magnetically attract at least some metallic debris from the drilling fluid.

In certain embodiments, the first elongated member and the second elongated member are located in the flow path between the separating mechanism and the outlet.

In other embodiments, the first elongated member and the second elongated member are removably positioned in the flow path.

In another embodiment, the first elongated member and the second elongated member are movably suspended in the flow path.

In yet another embodiment, the first elongated member and the second elongated member are movably suspended in a trough that is in the flow path.

In a fourth aspect, there is provided a method of manufacturing an apparatus to remove metallic debris from a drilling fluid that includes providing a first elongated member; providing a second elongated member; placing a first magnet in the first elongated member and sealing the first elongated member; and placing a second magnet in the second elongated member and sealing the second elongated member.

In certain embodiments, sealing the first magnet in the first elongated member and sealing the second magnet in the second elongated member includes coupling a first ends of the first and second elongated members to a first end member and coupling a second end of the first and second elongated members to a second end member.

In other embodiments, the method includes creating a first opening in the first end member and a second opening in the second end member.

In another embodiment, the method includes coupling a cord to the first and second opening. The cord may be configured to movably suspend the first and second elongated members.

In yet another embodiment, the method includes inserting epoxy into an interior channel of the first and second elongated member.

In still another embodiment, the method includes inserting a catalyst into the interior channel of the first and second elongated members.

In some embodiments, the method includes placing a plurality of magnets in the first and second elongated members.

In another embodiment, the method includes aligning the plurality of magnets into one or more rows in each elongated member.

In certain embodiments, the magnets are neodymium iron boron magnets.

Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE FIGURES

The accompanying drawings facilitate an understanding of the various embodiments.

FIG. 1 is a perspective, front view of an embodiment of an apparatus to remove metal debris from a drilling fluid.

FIGS. 2A, 2B, 2C, 2D, 2E and 2F are cutaway side views of embodiments of an apparatus to remove metal debris from a drilling fluid.

FIG. 3A is a perspective, front view of another embodiment of an apparatus to remove metal debris from a drilling fluid.

FIG. 3B is a cross section side view of the apparatus illustrated in FIG. 3A taken along line 3B-3B.

FIG. 3C is a perspective view of an embodiment of a plurality of magnets for use in connection with the apparatus of FIG. 3A.

FIGS. 4A, 4B, and 4C are cutaway side views of embodiments of an apparatus to remove metal debris from a drilling fluid.

FIG. 5A is a perspective, front view of another embodiment of an apparatus for removing metal debris from a drilling fluid.

FIG. 5B is a cross section side view of the apparatus illustrated in FIG. 5A taken along line 5B-5B.

FIG. 5C is a perspective view of an embodiment of a plurality of magnets for use in connection with the apparatus of FIG. 5A.

FIGS. 6A, 6B and 6C are cutaway side views of embodiments of an apparatus for removing metal debris from a drilling fluid.

FIG. 7 is a perspective, front view of another embodiment of an apparatus to remove metal debris from a drilling fluid.

FIG. 8 is a partially cut away perspective, front view of an embodiment of an apparatus to remove metal debris from a drilling fluid.

FIG. 9 is a cutaway side view of an embodiment of an apparatus to remove metal debris from a drilling fluid showing a flow path of drilling fluid.

FIG. 10 is a schematic side view of a drilling fluid cleansing apparatus including an embodiment of an apparatus to remove metal debris from a drilling fluid.

FIG. 11 is a schematic perspective view of another drilling fluid cleansing apparatus including an embodiment of an apparatus to remove metal debris from a drilling fluid.

FIG. 12 is a schematic perspective view of a trough of a drilling fluid cleansing apparatus including an apparatus to remove metal debris from a drilling fluid.

FIG. 13 is a perspective view of another drilling fluid cleansing apparatus including an apparatus to remove debris from a drilling fluid.

FIG. 14 is a schematic perspective view of a feeding cabin or “possum belly” including an apparatus to remove debris from a drilling fluid.

FIG. 15 is a partially perspective view of another embodiment of an apparatus to remove debris from a drilling fluid.

FIG. 16 is a block diagram illustrating an embodiment of a method for removing metallic debris from a drilling fluid.

FIG. 17 is a block diagram illustrating an embodiment of a method for manufacturing an apparatus to remove debris from a drilling fluid.

DETAILED DESCRIPTION

FIG. 1 is a perspective, front view of an embodiment of an apparatus 100 for removing metallic debris from a drilling fluid. The apparatus 100 may include a first end member 102, a second end member 104 spaced from the first end member 102, and one or more elongated members 106 extending between the first end member 102 and the second end member 104. As will be described in more detail below, the elongated members 106 may include one or more magnets 402 (see, e.g., FIGS. 3C, 5C and 8) or may otherwise exert a magnetic force to attract metallic debris from a drilling fluid that passes by the apparatus 100.

In some embodiments, the first and second end members 102 and 104 are located in a spaced apart relationship to allow drilling fluid to pass therebetween. As will be explained in more detail below, a distance between the end members 102 and 104 may be slightly less than the width of an outlet of a drilling fluid cleansing apparatus (see e.g., outlet 606 of drilling fluid cleansing apparatus 600 of FIG. 10) to allow the apparatus 100 to be located within a flow path of drilling fluid through the cleaning apparatus and to also make the apparatus 100 easily accessible to a user.

While the first and second end members 102 and 104 are cylindrical in the embodiment shown in FIG. 1, the end members 102 and 104 may be any suitable shape and size. For example, in some embodiments the end members 102 and 104 are square (as illustrated, for example, in FIG. 2E), rectangular or oval (as illustrated, for example, in FIG. 2F) in shape. In addition, the end members 102 and 104 may be any size. In some embodiments, for example, the end members 102 and 104 are cylindrical and have a diameter of about eight inches.

The end members 102 and 104 may be made of a metal material or any other suitable material, such as, for example, a plastic material or a composite material. In addition, the end members 102 and 104 may be magnetic or non-magnetic. For example, in some embodiments, the first and second end members 102 and 104 are made of a magnetized metal material. In other embodiments, the end members 102 and 104 include one or more magnets (see, e.g., magnets 402 in FIGS. 3C and 5C) positioned within the first and second end members 102 and 104. In such embodiments, the first and second end members 102 and 104 attract metallic debris from drilling fluid that passes between and around the first and second end members 102 and 104, as will be described in more detail below. In other embodiments, the first and second end members 102 and 104 are not magnetic and do not include magnets. The first and second end members 102 and 104 include surfaces 108 and 110, respectively, to which the elongated members 106 are attached.

The elongated members 106 extend between the first and second end members 102 and 104 and are configured to exert a magnetic force on metallic debris that pass in the vicinity of the elongated members 106. The elongated members 106 may be made of any suitable material, such as a metal material, and may each include an internal channel (see e.g., internal channels 404 in FIGS. 2A, 2B, 2C, 2D, 2E and 2F) that includes one or more magnets 402 (see e.g., magnets 402 located in internal channels 404 in FIGS. 3B, 5B and 8), as described in more detail below. The magnets 404 within the elongated members 106 exert a magnetic force on metallic debris that pass in the vicinity of the elongated members 106. In some embodiments, the elongated members 106 are also made of a magnetized material to increase the magnetic force applied by the elongated members 106.

In some embodiments, the magnetic force applied by the apparatus 100 is determined by the number of magnets 404 included in the apparatus 100. Thus, in some embodiments the total number of magnets 404 is increased to increase the magnetic force of the apparatus 100. In some embodiments, the total number of magnets 404 is increased by increasing the number of elongated members 106 that contain magnets 404 in the apparatus 100. In other embodiments, the number of magnets 404 is decreased to lower the total magnetic force of the apparatus 100 for applications in which a lower magnetic force is desired. In other embodiments, the magnetic force of the apparatus 100 is altered by selecting magnets 402 that have low or high magnetic force.

FIGS. 2A, 2B, 2C, 2D, 2E and 2F are cutaway side views of several embodiments of an apparatus 100 to remove metal debris from a drilling fluid. The elongated members 106 and the end members 102 of the apparatus 100 may have any suitable cross section shape. For example, in the embodiment shown in FIG. 2A the elongated members 106 have a circular cross section shape, while in the embodiments shown in FIGS. 2B and 2D-2F the elongated members 106 have a rectangular cross section shape. Additionally, in the embodiment of FIG. 2C the elongated members 106 have a triangular cross section shape. The elongated members 106 may also have other cross section shapes not illustrated herein, such as an elliptical shape or any other suitable shape.

While the elongated members 106 in each individual embodiment shown in FIGS. 2A, 2B, 2C, 2D, 2E and 2F are identical (i.e., all having a circular, square or triangular cross section in a particular embodiment), the elongated members 106 of a particular embodiment may have different cross section shapes, difference sizes and different lengths. For example, in one embodiment a first elongated member 106 has a circular cross sectional shape while the second and third elongated members 106 in the same embodiment have square cross sectional shapes.

Referring again to FIG. 1, the elongated members 106 may also be coupled to the end members 102 at any suitable position on the surfaces 108 and 110. For example, the elongated members 106 may be equally spaced radially around a central axis of the end members 102 and 104, as shown in FIGS. 2A, 2B, 2C and 2E. In other embodiments, the elongated members 106 may be spaced in other arrangements, such as, for example, the arrangement shown in FIGS. 2D and 2F. In addition, the positioning of the elongated members 106 on the first surface 108 need not be identical to the positioning of the opposite end of the elongated members 106 on the second surface 110. For example, in one embodiment the elongated members 106 are coupled to the first surface 108 so that the elongated members 106 are approximately 120 degrees from each other, as shown in FIG. 2A, while the opposite ends of same elongated members 106 are coupled to the second surface 110 in a different orientation, such as a linear orientation. As such, the elongated members 106 need not extend perpendicularly from the first and second surfaces 108 and 110 and, in some embodiments, may extend from the surfaces 108 and 110 at any other angle.

Furthermore, the apparatus 100 may include any number of elongated members 106. For example, the embodiments in FIGS. 2A, 2B and 2C include three elongated members 106; the embodiment of FIG. 2D includes six elongated members 106; the embodiment of FIG. 2E includes four elongated members 106; and the embodiment of FIG. 2F includes eleven elongated members 106 (see also, the embodiments of FIGS. 3A, 3B, 4A, 4B and 4C, which each include one elongated member 106; and the embodiments of FIGS. 5A, 5B, 6A, 6B and 6C, which each include two elongated members 106).

FIGS. 2A, 2B, 2C, 2D, 2E and 2F also illustrate various embodiments of the end member 102. The first end member 102 and the second end member 104 may have any suitable shape and size. For example, in the embodiments of FIGS. 2A, 2B and 2C, the first end member 102 has a circular shape; in the embodiment of FIG. 2D, the first end member 102 has a triangular shape; in the embodiment of FIG. 2E the first end member 102 has a rectangular shape; and in the embodiment of FIG. 2F the first end member 102 that has an oval shape. While the first end member 102 is shown in FIGS. 2A, 2B, 2C, 2D, 2E and 2F, the second end member 104 may also have any suitable shape and size and may be identical to the first end member 102 or may be different than the first end member 102 in a particular embodiment.

Referring now to FIGS. 3A and 3B, the apparatus 100 may include a single elongated member 106 that is centrally located on the end members 102 and 104. Referring specifically to FIG. 3B, in some embodiments the single elongated member 106 has a square cross section shape that is approximately 1 5/16 inch on each side, as illustrated by lengths 122. The elongated member 106 may be located approximately 3 1/32 inches from an outer edge of the end member 102, as illustrated by lengths 118 and 120, and the end member 102 may have a diameter of approximately eight inches, as shown by length 114.

Referring still to FIG. 3B, in some embodiments the end member 102 also includes an opening 412 for the placement of a hanging device, such as a cord or rope (see, e.g., the cord 416 in FIG. 8). In some embodiments, the opening 412 has a diameter of about ½ inch. In some embodiments, the opening 412 is spaced from a side edge of the end member 102 by about ¾ inches, as shown by length 116. In some embodiments, the cord 416 is rigid while in other embodiments the cord 416 is flexible. The cord 416 may be made of any suitable material, such as, but not limited to, metal, plastic, fabric, or a combination of materials. In some embodiments, the cord 416 is fastened to one or more of the end members 102 or 104 without the use of an opening 412. For example, in some embodiments the cord 416 is welded to one or more of the end members 102 or 104.

FIG. 3C illustrates a perspective view of an embodiment of a plurality of magnets 402 aligned in a row. As discussed in more detail below, the plurality of magnets 402 may be located within a channel 404 of the elongated member 106 of the apparatus 100 illustrated in FIGS. 3A and 3B. In some embodiments, the plurality of magnets 402 are aligned prior to placement within the channel 404 so that the magnets 402 remain aligned when inserted within the channel 404. As discussed above, each elongated member 106 may include any number of magnets 402.

FIGS. 4A, 4B and 4C illustrate cutaway side views of various embodiments of an apparatus 100 with a single elongated member 106. The elongated member 106 may be centrally located on the end member 102 and may have any suitable cross section shape. In some embodiments, for example, the single elongated member has a circular cross section shape, a square cross section shape or a triangular cross section shape, as illustrated in FIGS. 4A, 4B and 4C, respectively.

FIGS. 5A and 5B illustrate another embodiment of an apparatus 100 for removing metal debris from a drilling fluid. In some embodiments, the apparatus 100 includes two elongated members 106. Referring specifically to FIG. 5B, the elongated members 106 may be located approximately 3 11/32 inches from an outer edge of the end member 104, as shown by length 126. In some embodiments, the elongated members 106 are spaced from each other by a distance of about2 11/16 inches, as shown by length 128. In some embodiments, the distance 128 between the elongated members 106 is sufficient to allow a worker to place a rag or other cleaning device between the elongated members 106 to remove metal debris from the elongated members 106, as described in more detail below.

FIG. 5C is a perspective view of an embodiment of a plurality of magnets 402 aligned in two rows for placement within the two elongated members 106 of the apparatus 100 illustrated in FIGS. 5A and 5B. The apparatus 100 may include a row of magnets 402 in each elongated member 106. Each row of magnets 402 may include any number of magnets 402.

FIGS. 6A, 6B and 6C illustrate alternative embodiments of an apparatus 100 that includes two elongated members 106. As discussed above, the elongated members 106 may have any suitable shape, size and positioning on the end members 102 and 104. In the embodiments of FIGS. 6A, 6B and 6C, for example, the elongated members 106 have circular, square and triangular cross section shapes, respectively, and the elongated members 106 are positioned on the end member 102 so that a worker can place a cleaning mechanism, such as a cloth rag, between the elongated members 106 to clean the elongated members 106.

In other embodiments, the apparatus 100 may include any number of end members 102 and 104 and elongated members 106. For example, FIG. 7 is a perspective, front view of another embodiment of an apparatus 100 for removing metallic debris from a drilling fluid that includes a first end member 102, a second end member 104 and a third end member 302. The second end member 104 is located between the first end member 102 and the third end member 302 and the apparatus 100 include a first set 304 of elongated members 106 between the first and second end members 102 and 104, and a second set 306 of elongated members 106 located between the second and third end members 104 and 302. In other embodiments, the apparatus 100 may have additional sets of elongated members 106 and additional end members 102, 104 or 302.

FIG. 8 is a partially cut away perspective view of an embodiment of an apparatus 100 to remove metal debris from a drilling fluid. As described above, in some embodiments the elongated members 106 include interior channels 404 that includes one or more magnets 402. The magnets 402 may be organized into rows within the interior channels 404, or, in other embodiments, may be oriented in any other suitable orientation, such as, for example, a random placement in the interior channels 404. In some embodiments, each elongated member 106 includes more than one row of magnets 402.

The magnets 402 may be any suitable type of magnet 402 having any suitable magnetic strength. In some embodiments, the magnets are rectangular and are approximately 4 inches long. In some embodiments, the magnets 402 are neodymium iron boron magnets. In some embodiments, the magnets 402 are neodymium iron boron magnets with a coating of nickel to protect the magnet 404 from exposure to water, which may damage the magnet 404. In some embodiments, the nickel coating is approximately .005 inches thick.

In some embodiments, the interior channels 404 also include an adhesive 418, such as, for example, an epoxy. Once the adhesive 418 has cured within the channel 404, the adhesive 418 may hold the magnets 402 in place within the channel 404. Any suitable adhesive 418 may be used within the channels 404. In some embodiments, for example, the adhesive is an epoxy such as epoxy 50-3185. In some embodiments, the interior channel 404 also includes a catalyst (not shown), such as a catalyst number 190. In some embodiments, the catalyst reacts with the epoxy to harden the epoxy within the channels 404.

In some embodiments, the interior channel 404 is sealed to prevent entry of water, drilling fluid or contaminants within the channel 404. In certain embodiments, the interior channel 404 is sealed when the ends of the elongated members 106 are coupled to the first and second end members 102 and 104. When the interior channel 404 is sealed, the magnets 402 and other contents of the interior channels 404 may be protected from exposure to air, water, drilling fluid and other outside contaminants.

FIG. 9 is a cutaway side view of an embodiment of an apparatus 100 to remove metal debris from a drilling fluid showing a flow path 500 including flow path portions 502, 504, 506, 508, 510 and 512. In some embodiments, the flow path 500 is a path of used or new drilling fluid as it passes by the elongated members 106, for example, as the drilling fluid flows through a drilling fluid cleansing machine (see, e.g., the drilling fluid cleansing machine 600 illustrated in FIG. 10). In some embodiments, the drilling fluid may include metallic debris that are attracted by the magnetic forces exerted by the elongated members 106 and/or the end members 102 to adhere the metallic debris to the apparatus 100. The metallic debris in the drilling fluid may contact and removably adhere to an outer surface of the elongated members 106 or the end members 102 and 104, thus preventing the metallic debris from continuing to move with the drilling fluid. As described in more detail below, the apparatus 100 may then be removed periodically from the flow path 500 to allow a user to clean the metallic debris from the apparatus 100, thereby permanently removing the metallic debris from the flow path 500.

The flow path 500 need not move in a uniform direction and need not be a rapidly moving flow of material. In some embodiment, the flow path 500 includes flow portions 502, 504, 506, 508, 510 and 512 that flow between and around the elongated members 106 and/or end members 102 and 104. In some embodiments, the drilling fluid may flow between the elongated members 106, such as is shown by the flow portions 504, 506, 508, 510 and 512. In some embodiments, the drilling fluid may flow near the elongated members 106 but not between the elongated members 106, as shown by the flow portion 502. Drilling fluid may flow in multiple directions in the vicinity of the elongated members 106 and in some embodiments may flow in a direction opposite to that of the general flow path 500, such as is shown by the flow path 506. Drilling fluid that passes between elongated members 106 and/or end members 102 and 104 may be exposed to magnetic forces exerted by two or more elongated members 106 and/or end members 102 and 104, thus increasing the likelihood that the metallic debris will be attracted to an elongated member 106 and removed from the flow path 506. In some embodiments, by allowing drilling fluid to flow between elongated members 106 and end members 102 and 104, a greater volume of drilling fluid may be in close proximity to magnetic forces from the elongated members 106.

The flow portions 502, 504, 506, 508, 510 and 512 of the flow path 500 need not be identical to that shown in FIG. 5, and other flow paths 500 are within the scope of this disclosure. For example, in some embodiments, the flow path 500 is generally a flow of drilling fluid between an inlet and outlet of an apparatus for cleansing drilling fluid (see, e.g., FIG. 10 showing an inlet 604 and an outlet 606 of a drilling fluid cleaning apparatus 600), as will be described in more detail below. In addition, the flow path 500 need not always be in motion. For example, certain portions of the flow path 500 may be stationary for short or long periods of time, for example, the flow path of drilling fluid that sits in a feeding cabin of a drilling fluid cleansing apparatus (see e.g., FIG. 10 showing a feeding cabin 618, also called a “possum belly”).

FIG. 10 is a schematic view of a drilling fluid cleansing apparatus 600 including an apparatus 100 to remove metal debris from a drilling fluid. The drilling fluid cleaning apparatus 600 may include an inlet 604 to receive drilling fluid, a plurality of screens 610 to remove large debris from the drilling fluid, an outlet 608 for discarding large debris that have been removed from the drilling fluid, and an outlet 606 to expel cleaned drilling fluid from the drilling fluid cleansing apparatus 600. The arrows 612 illustrate the flow path of untreated drilling fluid, the arrows 614 illustrate the flow path of drilling cuttings that have been removed from the drilling fluid by the screens 610, and arrows 616 illustrate the flow path of the treated drilling fluid that has passed through the screens 610.

In use, the drilling fluid enters the apparatus 600 at the inlet 604 and travels into a feeding cabin 618, sometimes called a “possum belly.” The drilling fluid pools in the feeding cabin 618 until the drilling fluid begins to spill over a feeding ledge 620. The drilling fluid that spills over the feeding ledge 620 enters an area of the apparatus 600 called the screen box 622. The screen box 622 includes a plurality of screens 610 that are configured to remove debris from the drilling fluid and allow clean drilling fluid to pass through the screens 610 into the exit trough 624. In some embodiments, the screens 610 vibrate when the apparatus 600 is in operation to help separate large debris from the drilling fluid. In some embodiments, large debris are ejected from the apparatus 600 in the direction of the arrows 614 into a debris holding area (not shown in FIG. 10).

Treated drilling fluid passes through openings in the screens 610, as shown by the arrows 616, and is collected in an exit trough or hopper 624. The drilling fluid in the trough 624 moves toward the outlet 606 where the drilling fluid may be transported to another location for reuse, further cleansing operations or to be discarded.

In some embodiments, the apparatus 100 is located in or near the outlet 606 to help remove any metallic debris that remain in the drilling fluid after the drilling fluid has passed through the screens 610. As the drilling fluid flows through the outlet 606, the apparatus 100 attracts metallic particles due to the magnetic forces exerted by the magnets 402 (not illustrated in FIG. 10) in the elongated members 106. In some embodiments, the metallic particles stick to the surfaces of the apparatus 100, such as the surfaces of the elongated members 106, to remove the metallic particles from the drilling fluid. Periodically, workers remove the apparatus 100 from the exit trough 624 to remove the metallic debris from the surfaces of the apparatus 100, for example, by wiping a cloth rag across the surfaces of the elongated members 106. Once the workers have cleaned the apparatus 100, the apparatus 100 is reinserted into the exit trough 624.

In some embodiment, more than one apparatus 100 is included in the flow path of the drilling fluid. For example in some embodiments, an apparatus 100 is included in the feeding cabin 618 and another apparatus 100 is included in or near the outlet 606. In addition, the apparatus(s) 100 may be positioned within the flow path at any suitable orientation (i.e., upright, horizontal, etc.). For example, in the embodiment illustrated in FIG. 10 the apparatus 100 is positioned so that the elongated members 106 are horizontal and span most of the width of the outlet 606. In other embodiments, the elongated members 106 may be vertically positioned (see e.g., FIGS. 13 and 14 showing the apparatus 100 positioned in the feeding cabin 618 so that the elongated members 106 are vertically oriented) or may be positioned at any other suitable orientation. In other embodiments, the drilling fluid cleansing apparatus 600 may have slots or other holding mechanisms (not shown) to hold the apparatus 100 in a particular position. For example, in some embodiments a user places the apparatus 100 within the outlet 606 by sliding the end members 102 and 104 into corresponding slots (not shown) in the walls of the outlet 606. In other embodiments, the apparatus 100 is suspended within the drilling fluid cleansing apparatus 600 by a cord 416, as illustrated in FIG. 8.

FIG. 11 is a schematic perspective view of another drilling fluid cleansing apparatus 600 including an embodiment of an apparatus 100 to remove metal debris from a drilling fluid located between the outlet 606 and the exit trough 624 (not shown in FIG. 11). The drilling fluid cleaning apparatus 600 may include a feeding cabin 618 into which drilling fluid is pumped, a feeding ledge 620 that allows the drilling fluid to spill over onto a screen 610, as shown by arrows 628, an outlet for large debris that have been removed from the drilling fluid, as shown by arrows 626, and an outlet 606 to expel cleansed drilling fluid. In use, the drilling fluid enters the apparatus 600 and travels into the feeding cabin 618. The drilling fluid pools in the feeding cabin 618 until the drilling fluid spills over a feeding ledge 620. The drilling fluid that spills over the feeding ledge 620 contacts the screen 610, which may be coupled to a vibration mechanism to cause the screen to vibrate. Large debris are ejected from the apparatus 600 in the direction of the arrows 626 into a debris holding area (not shown). Treated drilling fluid that passes through the screens 610 is collected in an exit trough or hopper (not shown). The drilling fluid in the trough 602 moves toward the outlet 606 where it contacts the apparatus 100, which may be located inside of the outlet 606, as shown in FIG. 11, directly within the outlet 606, outside of the outlet 606 or at any other location in the fluid flow path. In some embodiments, the apparatus 100 is sized such that the end members 102 and 104 contact walls of the outlet 606. In other embodiments, the apparatus 100 is smaller than the width of the outlet 606 so that the apparatus 100 is movable in the outlet 606, as illustrated in FIG. 11.

FIG. 12 is a schematic perspective view of an exit trough 624 that includes an apparatus 100 to remove metal debris from a drilling fluid. As discussed above, the apparatus 100 can be located within the exit trough 624 and inside of the outlet 606. As illustrated in FIG. 12, the apparatus 100 may be located at or near the lowest portion of the exit trough 624 so that the fluid in the exit trough 624 flows toward the apparatus 100, thus increasing the amount of fluid that passes in close proximity to the elongated members 106 before flowing through the outlet 606.

While FIGS. 10, 11 and 12 illustrate embodiments of a cleaning device 600 in which the apparatus 100 is positioned in or near the exit trough 624, the apparatus 100 can be located at other positions in a fluid flow path of the drilling fluid. In other embodiments, the apparatus 100 may be located at any point in the flow path 500 where the elongated members 106 can magnetically attract metallic debris from the drilling fluid to remove the metallic debris from the drilling fluid. For example, in some embodiments the apparatus 100 is located in the flow path of the drilling fluid at any point between the screen(s) 610 and the outlet 606. In other embodiments, the apparatus 100 is located at any point between the inlet 604 and the screen(s) 610. In yet other embodiments, the apparatus 100 is located in the flow path of the drilling fluid just before, or just after, the flow the drilling fluid enters, or exits, the cleaning device 600.

In addition, while FIGS. 10-12 illustrate embodiments in which the apparatus 100 is positioned in a horizontal orientation, the apparatus 100 may be positioned at any other suitable orientation. For example, in the embodiments illustrated in FIGS. 13 and 14 the apparatus 100 is located in the feeding cabin 618 (or “possum belly”) in an upright orientation so that one of the end members 102 or 104 contacts a floor 632 of the feeding cabin 618. In some embodiments, the apparatus 100 includes a cord 416 that is secured to one or both of the end members 102 and 104. The cord 416 may be positioned to allow a worker to remove the apparatus 100 from the feeding cabin 618 by pulling on the cord 416.

FIG. 15 is an exploded view of another embodiment of an apparatus 100 to remove debris from a drilling fluid. In some embodiments, the apparatus 100 includes a set of first end members 102 and 104 that include openings 132 corresponding to the positioning of the elongated members 106. The apparatus 100 also includes a set of additional end members 128 and 130. In practice, a worker secures the first set of end members 102 and 104 to the elongated members 106 so that the openings 132 align with the internal channels 404 of the elongated members 106. The worker then secures one of the additional end members 128 or 130 to the corresponding end member 102 or 104. The worker then inserts an epoxy into the channels 404 and aligns a first set of magnets 402 in a row. The worker then places the row of magnets 402 within the internal channel 404 containing the epoxy and then inserts an additional amount of epoxy into the channel.

The worker then follows the same steps to insert epoxy and magnets 402 into the internal channels 404 of the other elongated members 106. In some embodiments, the worker or another worker holds the magnets 402 that have already been inserted into the apparatus 100 while the other magnets 402 are placed into the apparatus 100 to prevent the magnets 402 from forcing each other out of the apparatus 100. The worker then secures the other additional end member 128 to the remaining end member 102 to seal the openings 132. As such, the magnets 402 (and the epoxy) are secured within the elongated members 106.

FIG. 16 illustrates a method 800 of removing metallic debris from a drilling fluid. The method 800 may include flowing at least some of the drilling fluid past a first elongated member 106 to attract at least some of the metallic debris from the drilling fluid to the first elongated member 106, as shown at block 802. The method may also include flowing at least some of the drilling fluid past a second elongated member 106 to attract at least some of the metallic debris to the second elongated member 106, as shown at block 804. As discussed above, the first and second elongated members 106 may each include one or more magnets 402 and/or may otherwise exert a magnetic force on the surrounding area. The elongated members 106 may be located in a drilling fluid cleansing apparatus 600 or may be located in another location in a drilling fluid processing system, for example, upstream or downstream from a drilling fluid cleansing apparatus 600.

In some embodiments, the method 800 may also include locating the first and second elongated members 106 in a flow path of the drilling fluid between a separating mechanism, such as a screen 610, and an outlet 606 of a drilling fluid cleansing apparatus 600. The method 800 may also include removing at least some of the metallic debris from an exterior surface of the first and second elongated members 106 by wiping the first and second elongated members 106 with a rag.

FIG. 17 illustrates a method 900 of manufacturing an apparatus 100 to remove metallic debris from a drilling fluid. The method 900 may include providing a first elongated member 106, providing a second elongated member 106, securing the first elongated member 106 to a first end member 102 and securing the second elongated member 106 to the first end member 102, as shown at blocks 902, 904, 906 and 908, respectively. The method 900 may also include placing an epoxy or other adhesive 418 into internal channels 404 of the elongated members 106. The method 900 also includes placing a magnet 402 in each of the elongated members 106, as shown at block 910. The method 900 may then include sealing the magnet 402 within the elongated member 106, as shown at block 912. In some embodiments, the magnet 402 is sealed within the elongated member 106 by coupling a second end member 104 to the ends of the first and second elongated members 106 opposite from the first end member 102.

In some embodiments, the method 900 also includes placing additional magnets 402 within each elongated member 106. In some embodiments, a first row of magnets 402 is placed within a first elongated member 106. In some embodiments, the first row of magnets 402 is held in place within the first elongated member 106 while a second row of magnets 402 is placed within a second elongated member 106 to prevent the first row of magnets 402 from being ejected from the first elongated member 106 by interaction of the magnetic forces of the first and second rows of magnets 402.

In addition, in some embodiments the method 900 includes inserting an epoxy or other adhesive into the elongated members 106 before and/or after the magnets 402 are placed within the elongated members 106. In some embodiment, the method 900 also includes creating a first opening 412 in the first end member 102 and a second opening 414 in the second end member 104, and coupling a cord 416 to the first and second openings 412, as shown in the embodiment illustrated in FIG. 8. The method 900 may also include inserting a catalyst into the interior channel 404 of the first and second elongated members 106 to harden the epoxy. The hardened epoxy may hold the magnets 402 in place within the interior channels 404 of the elongated members 106.

In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below”, “top” and “bottom” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims

1. An apparatus for removing metallic debris from a drilling fluid, the apparatus comprising:

a first end member;

a second end member; and

two or more elongated members extending between the first end member and the second end member, wherein the two or more elongated members include a magnet and the two or more elongated members are spaced from each other to allow a drilling fluid to flow between the two or more elongated members.

2. The apparatus according to claim 1, wherein the first end member and the second end member are cylindrical.

3. The apparatus according to claim 1, wherein the two or more elongated members comprise three elongated members.

4. The apparatus according to claim 1, wherein the elongated members are substantially equally spaced radially around a central axis of the end members.

5. The apparatus according to claim 1, wherein the elongated members have an interior channel and the magnet is located in the interior channel, and further comprising an adhesive positioned in the interior channel.

6. The apparatus according to claim 5, wherein the adhesive includes an epoxy and a catalyst.

7. The apparatus according to claim 5, wherein the interior channel is substantially sealed.

8. The apparatus according to claim 7, wherein the interior channel is sealed by the first and second end members being coupled to the two or more elongated members.

9. The apparatus according to claim 1, wherein the magnet includes neodymium.

10. The apparatus according to claim 1, wherein a distance between the end members is slightly less than the width of a drilling fluid outlet of a drilling fluid cleansing machine.

11. A method of removing metallic debris from a drilling fluid, the method comprising:

flowing a drilling fluid past a first elongated member to attract at least some metallic debris from the drilling fluid to the first elongated member;

flowing the drilling fluid past a second elongated member to attract at least some metallic debris from the drilling fluid to the second elongated member;

removing the first and second elongated members from a flow path of the drilling fluid; and

removing at least some metallic debris from the first and second elongated members.

12. The method according to claim 11, further comprising flowing at least some of the drilling fluid between the first elongated member and the second elongated member.

13. The method according to claim 11, further comprising flowing at least some of the drilling fluid past a third elongated member to attract at least some of the metallic debris to the third elongated member.

14. The method according to claim 11, further comprising locating the first elongated member and the second elongated member in a feeding cabin of a drilling fluid cleansing machine.

15. The method according to claim 11, further comprising locating the first and second elongated members in a drilling fluid outlet of a drilling fluid cleansing machine.

16. The method according to claim 11, further comprising locating the first and second elongated members in the flow path of the drilling fluid between a screen and a drilling fluid outlet of the drilling fluid cleansing machine.

17. A method of manufacturing an apparatus to remove metallic debris from a drilling fluid, the method comprising:

providing a first elongated member;

providing a second elongated member;

coupling a first magnet to the first elongated member; and

coupling a second magnet to the second elongated member.

18. The method according to claim 17, wherein coupling the first magnet to the first elongated member includes sealing the first magnet in a volume within the first elongated member, and coupling the second magnet to the second elongated member includes sealing the second magnet in a volume within the second elongated member.

19. The method according to claim 18, wherein sealing the first magnet in a volume within the first elongated member and sealing the second magnet in a volume within the second elongated member comprises securing a first end member to a first end of the first and second elongated members and securing a second end member to an opposite, second end of the first and second elongated members.

20. The method according to claim 17, further comprising coupling an elongated member to at least one of the first end plate and the second end plate, wherein the elongated member is configured to move the apparatus from a first position to a second position.