US20130284422A1

US20130284422A1 - Integrated fluid filtration and recirculation system and method

Info

Publication number: US20130284422A1
Application number: US13/925,255
Authority: US
Inventors: William O. Irvine
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-08-04
Filing date: 2013-06-24
Publication date: 2013-10-31

Abstract

An integrated fluid filtration and recirculation system and method are provided for re-circulating and filtering fluid that is used in well cleaning operations. The system is incorporated within an enclosure, which is transportable, such as on a vehicle trailer. The system has power generation capability, thereby making the system capable of operating as a stand-alone unit. Chemicals may be infused into the filtered fluid from an integral chemical supply allowing the system to also function as a treatment facility for the fluid. The components of the system are arranged in a linear fashion that enables the system to maintain a minimum profile for transport upon a conventional trailer, yet the system provides enough room within the enclosure to allow operators to repair/inspect each of the system components. The enclosure may be climate controlled, and the enclosure may include removable panels for operation of the system in temperate conditions when climate control is unnecessary.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 12/535,565 filed on Aug. 4, 2009, now U.S. Pat. No. 8,469,100, the disclosure of which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to self-contained, mobile, fluid filtration systems, and more particularly, to an integrated fluid filtration and recirculation system and method especially adapted for filtration and recycling of cleaning fluids used to clean the bore of a well.

BACKGROUND OF THE INVENTION

A number of systems have been developed for evacuating accumulations of blockages in wellbores to include oil and gas producing wells. The blockages may include accumulations of sediments and other solids generated from the well. A well is typically lined at the upper portion with a casing, and the down-hole portion is lined with metallic, plastic, or other liners, sometimes referred to as “well tubulars”. The tubulars may be in the form of production tubing, and slotted or wire-wrapped liners. The well tubulars may be particularly susceptible to corrosion, and deposits may develop on the tubulars such as silicates, sulfates, sulfides, carbonates, calcium and organic growth. One solution for performing well cleaning operations is to utilize a cleaning implement placed down-hole that also carries a cleaning solution. The cleaning implement forms the distal end of a tubular member placed down-hole, referred to as coiled tubing. The coiled tubing is placed into the well to perform the cleaning operation to include the injection of treating and cleaning fluids, which remove blockages and otherwise clean the well tubulars. The circulation and cleaning fluid may include water, acid, foam, chemical cleaning solutions, and corrosion inhibitors.
It is desirable to perform an efficient well cleaning operation in which the coiled tubing is advanced into the well as quickly as possible, and then the fluid is injected into the well. The cleaning implement in conjunction with the cleaning fluid provides both mechanical and fluid/chemical cleaning which under most circumstances adequately cleans the wellbore.
Depending upon the depth and number of wells to be cleaned, a significant amount of cleaning fluids may be required to adequately clean the targeted wells. Because of environmental concerns in most locations, the cleaning fluids cannot be disposed of by allowing the fluid to be dumped onto the surrounding land. Therefore, there is an operational requirement to prevent the cleaning fluids from contacting the ground. Significant measures are taken to retrieve the used cleaning fluids in order to dispose of the fluids in an environmentally responsible manner.
One system disclosed for cleaning a well is found in U.S. Pat. No. 4,919,204. This reference more specifically discloses a cleaning apparatus for pressurized cleaning of well flow conductors. The apparatus provides cleaning of the conductors by use of the apparatus in combination with high pressure directed fluid jets that flow through the apparatus. Rotation of the cleaning apparatus can also be used for combined mechanical and hydraulic drilling to remove deposits from within the well flow conductors. The reference discloses coiled tubing mounted on a reel, and the reel itself is mounted on a vehicle. A manifold is connected to the coiled tubing. The manifold includes the necessary pumps, valves, and fluid reservoirs to discharge high pressure cleaning fluid through the coiled tubing into the wellbore.
Another example of a system for cleaning a well is disclosed in the U.S. Pat. No. 7,549,468. Specifically, the reference discloses a coiled tubing injector system which includes transport trailer components for separate transfer to and from a drilling site. Each component is taken to the site with its own transport tractor, a first component including a coil storage reel and a second component including a tubing injector carried on a mast which is raised from a horizontal transport position, through a stabbing and unstabbing position to a raised working position. When the components are arranged together in an end-to-end with the mast in a stabbing position, a tube gripping member is positioned between the storage reel and tubing injector for controlling the handling of a free end of the stored tubing for stabbing and unstabbing of the tubing injector
Other examples of wellbore cleaning devices include the U.S. Pat. Nos. 4,744,420 and 7,377,283.
As environmental regulations become more stringent, particularly in areas such as the Arctic, extreme measures have to be taken to prevent the inadvertent spillage of any cleaning fluid. The cleaning fluid cannot be permanently stored and treated at the well location and, therefore, once the cleaning fluid is spent, the cleaning fluid must be trucked offsite to a treatment facility. Often times, the treatment facility is many hundreds of miles from the well locations. Thus, one significant problem with well cleaning operations is the time and expense involved with trucking the needed cleaning fluid to and from the well locations.
Therefore, there is a need to provide a well cleaning system in which the logistics associated with use of the cleaning fluid are simplified and made more efficient. Furthermore, there is also a need to greatly conserve the use of the cleaning fluid, not only for purposes of addressing the logistical concerns, but also to reduce the risk that a significant amount of cleaning fluid could be inadvertently spilled.
There is also a need to provide an integrated cleaning solution in which the system can be easily transported to remote locations where vehicle access is limited to off-road type vehicles or vehicles that otherwise can travel on unimproved roads.
There is also a need to provide a cleaning solution that is self contained and automated which reduces manpower requirements and allows remote control of the system which may be installed at remote geographical locations.

SUMMARY OF THE INVENTION

In accordance with the present invention, a system and method are provided for an integrated fluid filtration and recirculation system that is especially adapted for filtering and re-circulating well cleaning and treatment fluid (referred to hereinafter collectively as “cleaning fluid”). With the method and system of the present invention, well cleaning fluid may be conserved by filtering and re-circulating used cleaning fluid back to the well for further cleaning operations. Thus, the cleaning fluid may be recycled a number of times before having to be evacuated from the site. The filtering and recycling of the cleaning fluid greatly conserves the amount of cleaning fluid required, and provides great economic savings and logistical savings with respect to the effort otherwise necessary to truck the cleaning fluid to and from the well locations.
The integrated fluid filtration and recirculation system of the present invention is characterized by a self-contained, automated, mobile/transportable, and efficiently sized system in which the cleaning fluid can be filtered and treated to a degree so that it may be reused in a number of subsequent cleaning cycles.
The system of the present invention includes a power generation capability for powering a pump which is capable of circulating the fluid from an intake where spent/used cleaning fluid arrives from the wellbore. The used fluid or contaminant fluid stream passes through a series of filtration elements which effectively filter the cleaning fluid so that the cleaning fluid may be reintroduced into the coiled tubing for subsequent cleaning operations.
The filtration assembly includes a primary or coarse filter that removes larger sized solids, and a secondary filtration group that provides filtration for finer particles, as well as removable of other unwanted chemical and organic contaminates in the fluid stream. The power generation capability is in the form of a generator unit that is co-mounted along with the filtration assembly within a common enclosure.
The enclosure can be insulated depending upon the environment in which the enclosure is used. The enclosure may have integral heating and cooling capabilities, such as an electric heater and an electrical air conditioning unit powered by the generator. Thus, the enclosure can be habitable, even in the most extreme climate conditions.
The enclosure itself is mounted upon a skid or base which is sized to be conveniently mounted on a standard sized hauling platform. The generator and filtration assembly are arranged so that they provide an elongated, linear configuration that is adapted for mounting on the skid/base that can be mounted upon a surface/platform that is not oversized and is capable of being transported without any size restrictions according to highway requirements. For example, the surface may be a flat bed trailer, or the system may be mounted to a hauler truck. More specifically, the generator and the filter assembly are linearly aligned and spaced from one another so that the generator and filtration assembly may be mounted for transport, yet maximum room is provided for operators to move within the enclosure that houses the generator and filtration assembly.
In one preferred embodiment of the enclosure, it may include removable panels or doors that enable operators to freely access the filtration assembly, generator, main controller, and other components of the system. For this embodiment, it is well adapted for use of the invention in temperate climates.
In another preferred embodiment of the enclosure, it may include a plurality of access panels and doors, but designed in a manner that the panels and doors providing access to the interior of the enclosure can be closed and sealed. In this embodiment, the enclosure is well adapted for use in extreme climates, such as the Arctic in which cold temperatures and moisture could damage system components, or such as humid tropical climates in which heat and moisture could also damage system components as well. In this second embodiment, the access doors and panels enable an operator to gain access to the interior of the enclosure, but also provide the operator with the capability to easily close and seal the doors/panels.
Yet additional features that are incorporated on the enclosure include exterior lights for night operations or other limited visibility operations. Another feature is the provision of one or more emergency stops switches mounted on the exterior of the enclosure enabling the operator to shut down the system in the event of an emergency, such as a fluid spill or fire.
In order to prevent exhaust gases from the generator from polluting the interior space of the enclosure, an exhaust stack is provided that isolates the exhaust from the generator and conveys the exhaust outside of the enclosure. The exhaust stack may have a variable length to optimally evacuate exhaust. For example, in windy conditions, it may be desirable to extend a length of the exhaust stack so that swirling winds do not carry exhaust fumes back into the enclosure through an open access panel or door.
By the construction of the enclosure, it is apparent that the enclosure has a number of features that allow it to be used in different climatic conditions from freezing Arctic weather to tropical areas.
The fuel that powers the generator can be drawn directly from another vehicle by an auxiliary fuel line which interconnects the fuel system of the vehicle to the generator. Alternatively, a smaller fuel storage tank may be incorporated on the enclosure such as an exposed fuel tank mounted to the end of the enclosure closest to the generator or the fuel tank may be stored beneath the generator.
The system can be monitored and operated by a master or main electronic controller that can control a number of functions to include the operation of the generator, the operation of the filtration assembly, the heating/cooling of the enclosure, and various alarm conditions that can be used to shut the system down or to otherwise manipulate the system based on the volumetric and flow rate needs of the particular well being serviced.
The cleaned fluid or filtrate stream may be further treated by the introduction of additives into the filtrate stream. A dosing pump is used to convey the additives to the filtrate stream prior to the filtrate stream being conveyed back to the coiled tubing.
The present invention provides a method for cleaning, treating and re-circulating fluid for purposes of maintenance of a well. The system is self contained, transportable, and adaptable for use in varying climatic conditions.
In sub-combination, the invention also provides a functional and unique filtration assembly that is especially adapted to be trailer mounted.
In another aspect, the invention can be considered in combination with a coiled tubing system to provide a complete solution for well cleaning operations.
These and other aspects and advantages of the present invention will become clearer in a review of the following drawings, taken in conjunction with the detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a well and wellhead being serviced by a coiled tubing workstation including the integrated fluid filtration and recirculation system of the present invention;

FIG. 2 is a perspective view of the system of the present invention as incorporated within an enclosure in a first embodiment of the enclosure;

FIG. 3 is a schematic diagram of the filtration assembly of the system;

FIG. 4 is a perspective view of the filtration assembly;

FIG. 5 is a reverse perspective view of the filtration assembly;

FIG. 6 is an elevation view of the filtration assembly;

FIG. 7 is a reverse elevation view of the filtration assembly;

FIG. 8 is an elevation view of one side of the enclosure in a second embodiment;

FIG. 9 is an elevation view of the other side of the enclosure of FIG. 8;

FIG. 10 is a side elevation view of one end of the enclosure of FIG. 8; and

FIG. 11 is a side elevation view of the other end of the enclosure of FIG. 8.

DETAILED DESCRIPTION

FIG. 1 illustrates a well 100 including a wellhead 102 that services a wellbore 104 that has been drilled. The well 100 may be, for example, a gas or oil producing well. A well casing 105 covers the wellbore 104. The wellbore 104 may be lined down-hole with various forms of tubulars (not shown). An injector assembly 106 is provided in the wellhead 102 for injecting cleaning fluid through coiled tubing 110 that has been placed in the wellbore. A cleaning apparatus 108 may be disposed at the distal end of the coiled tubing 110, and the apparatus 108 constitutes the most forward portion of the coiled tubing advanced through the wellbore. One or more control valves 112 may control the amount of cleaning fluid introduced through the coiled tubing 110. The cleaning fluid is introduced through the coiled tubing and strikes the wellbore once it discharges at the location of the cleaning apparatus 108. The used, discharged fluid then fills the wellbore and is evacuated through return line 114. Depending upon the type of cleaning apparatus, the used fluid may also be pumped to the surface through another line (not shown) placed coaxially within the coiled tubing. One or more transport pumps (not shown) may be incorporated with return valve 116 in order to transport the used/spent cleaning fluid to a pre-treatment station 20. The pre-treatment station 20 may be, for example, a settling tank. The fluid is then conveyed from the pre-treatment station through inlet lines 22 connected to inlet fittings 23 which in turn connect to the filtration assembly 10.
The coiled tubing 110 is paid-out from a dispensing reel 122 which may be, for example, mounted on a vehicle 120. The vehicle 120 may include a manifold (not shown) for receiving filtered/treated cleaning fluid through outlet or discharge line 76 connected to an outlet fitting 25, which thereby reintroduces the filtered/treated cleaning fluid for subsequent cleaning operations.
Referring also to FIG. 2, the system of the present invention is integrated with an enclosure 160. The filtration assembly includes a primary filtration station 12 and a secondary filtration station 14. A generator 176 provides power for a filtration pump 30 which circulates the fluid through the filtration assembly 10. The spent/used cleaning fluid enters the filtration assembly through one or more inlet lines 22. The filtered cleaning fluid or filtrate stream exits the filtration assembly through discharge line 76 that interconnects the filtrate stream with the manifold of the coiled tubing dispenser 122.
With respect to the construction of the enclosure 160, it provides a convenient, economical, and adaptable solution for cleaning/treating a fluid circulated through the filtration assembly. The enclosure is characterized by a roof 162, sidewalls 164, and an internal fire rated dividing wall 166 that separates two rooms, one room which houses the generator 176, and the other room which houses the filtration assembly. Respective doors (not shown) are used to access each of the rooms. The enclosure may be completely enclosed by sidewalls, or one or more of the sidewalls may incorporate removable panels (not shown), thereby exposing the generator and filtration assembly. In temperate climates, the removable panels may be advantageous, while providing a completely closed enclosure may be an optimal solution for extreme climate conditions, such as Arctic or desert conditions. As shown, two side openings 168 are provided, and these may be closed or may receive the removable panels. FIG. 2 also illustrates one end opening 170 which may receive either a removable panel or an access door.
A main control panel 174 can be mounted on the internal fire rated dividing wall as shown. The control panel 174 houses the main controller 200. The main control panel may include various indicator lights and an annunciator for providing an audible warning regarding the status of the system. The functions of the main controller 200 are discussed further below. Optionally, the generator 176 may have its own generator control panel 178 that allows local operation and monitoring of the generator 176. Two operators O1 and O2 are shown attending to the system. The enclosure is sized so that the operators have adequate room to access system components for repair, operation, and preventative maintenance. Although two operators are shown for purposes of illustrating the relative size of a person as compared to the size of the enclosed space provided by the enclosure, it shall be understood that one main objective of the main controller 200 is to provide an automatically controlled system which minimizes the necessity for operators to attend to the system. Of course, some preventative maintenance may have to occur over time, but the system does not require monitoring by an operator on a continual basis.
The generator and filtration assemblies are both mounted on a common pallet or skid 182. This pallet 182 is sized to fit within the dimensions of the trailer or haul vehicle carrying the system. For example, a standard trailer of a tractor-trailer rig may have a dimension of approximately 52 feet in length and 8.5 feet in width. The pallet 182 is sized to fit within this profile or a smaller length. A pair of hoisting bars 184 is disposed at opposite ends of the pallet, which enables the pallet to be lifted and moved from the trailer/vehicle that carries the system.
The lower portion of the enclosure includes raised edges constituting a spill containment lip that prevents fluids leaking from the generator or filtration assembly from spilling out of the enclosure onto the surrounding ground. The spill containment lip may be sized in height to accommodate a worst case scenario, i.e., a scenario in which substantially all of the fluids in the filtration assembly at any particular time were spilled to include the fluid being filtered as well as operating fluids such as hydraulic fluid and fuel. Thus, the height of the spill containment lip would be sized as a function of the volume necessary in the filtration assembly room to capture the fluid.
Each of the rooms also includes respective heating/cooling vents 188 which communicate with integral heating elements (not shown) and/or air conditioning elements (not shown). These heating/cooling units could be mounted to the ceiling or the sidewalls.
A bulkhead support 180 is located on both opposite sides of the walls of the enclosure. The supports 180 include one or more openings that receive the inlet/discharge lines from the filtration assembly. FIG. 2 only shows one support 180, but it shall be understood that the opposite side of the enclosure would also have a bulkhead support 180 for receiving the inlet/discharge lines extending towards that side of the enclosure. Providing dual inlet and discharge bulkhead supports on opposite sides of the enclosure allows the enclosure to be used in different orientations where the enclosure may be more easily installed to fit within existing equipment arrangements at a jobsite or other locations.
FIG. 1 shows the enclosure 160 of the present invention mounted on a trailer 190. However, it shall be understood that the enclosure 160 can also be mounted on a hauler truck or other flat surface that is sized to meet federal and state highway size specifications in order to avoid special permits for oversized loads. It should also be understood that since the enclosure is skid mounted, the enclosure could be placed directly on the ground, could remain on the trailer in which it was transported, or could be placed on an elevated support above the ground. Selecting the particular height of the enclosure in use can assist in operation of the system by affecting the hydraulic head for fluid flow. For example, if the incoming fluid did not have significant hydraulic head, and to avoid having to use intermediate pumps between the well site and the enclosure, it may be desirable to place the enclosure on the ground to minimize elevation. In another example, if hydraulic head from the incoming fluid was not an issue, then it may be desirable to keep the enclosure mounted on the trailer. Regardless of the particular jobsite, the provision of the dual inlet and discharge bulkhead supports located near the bottom end of the enclosure provides a very low elevation for hookup of fluid lines to assist in fluid flow in those situations in which there is a low hydraulic head for incoming fluid.
Referring to FIG. 3, a schematic diagram is provided of the filtration assembly 10 of the present invention. First, the transfer line 114 carries the spent/used cleaning fluid from the wellbore to the pre-treatment station 20. From the pre-treatment station, inlet line 22 carries the used fluid through one or more separate inlet valves 26. The used fluid then flows through three-way inlet valve 28 to pump 30. An alternate inlet may be provided in the event there is more than one source of spent/used fluids, such as from multiple pre-treatment stations. Pump 30 conveys the used fluid through delivery line 32 to the primary filtration station 12. The primary filtration station 12 includes a primary filter 36. The used fluid enters the filter 36 through primary filter intake valve 34. The used fluid is filtered in the filter 36. The primary filtered fluid exits the filter 36 and travels through primary filter discharge valve 38 and then through primary filtered fluid line 54.
Primary filter 36 can be selected to provide the necessary coarse filtration. One example of a range of pore sizes for the filter 36 could be in the range of 10-25 microns. This range may provide adequate coarse filtration for many oil well applications however the particular range can be adjusted for the particular application. The primary filter 36 may also have an automatic backwash feature to periodically clean the filter. The construction of the filter element(s) within the filter 36 can also be chosen to maximize filtration results, and one example of a filter construction is one that has a woven wire mesh filter arrangement. In a backwash cycle, the filter is cleaned to remove the arrested contaminant particles, and primary filter backwash valve 40 is actuated to enable the backwash fluid containing the loosened particles from the filter to travel through primary waste line 52. Primary waste line 52 may also have its own dedicated discharge valve 84. The downstream side of the discharge valve communicates with a receptacle (not shown) which captures the waste concentrate.
A primary filter bypass line 48 is provided to enable fluid to bypass the primary filter 36. Primary filter bypass valve 46 is opened to receive the bypass fluid when primary filter intake valve 34 is closed to thereby facilitate the bypass. A check valve 50 is provided to prevent backflow through the bypass line 48. The bypass line 48 connects to the primary filtered fluid line allowing the fluid to flow directly to the secondary filtration station 14. This bypass function may be desirable when, for example, the used fluid does not require primary filtration to remove larger particles. The bypass can also be useful in the event of an obstruction within or upstream of the primary filter.
A diversion line 42 is also provided to divert a desired flow of fluid in order to flush the primary waste line 52, or to prevent freezing of the primary waste line 52 in the event the filtration assembly was inadvertently exposed to conditions which otherwise could freeze the lines. As shown, diversion line 42 connects to the primary waste line 52 downstream of diversion valve 44. Diversion valve 44 is opened to allow a desired amount of flow through diversion line 42 into the primary waste line 52. Thus, the diversion line 42 provides additional conveying fluid so that the concentrated waste does not obstruct line 52, since primary waste line 52 does not typically have a steady stream of fluid passing therethrough and the waste line is therefore more susceptible to becoming clogged by solids buildup.
From the primary filtered line 54, the primary filtered fluid then passes through the secondary filter inlet valves 56 into the secondary filtration station 14. The station 14 as shown comprises a plurality of secondary/fine filters 60. Within the plurality of fine filters 60, the final or secondary filtration occurs. One example of a range of pore sizes for the secondary filters 60 could be in the range of 3-5 microns. This range may provide adequate fine filtration for many oil well applications however this particular range can also be adjusted for the particular application. The finely filtered or secondary filtered fluid then passes through secondary filtrate discharge valves 62 and into the secondary filtrate line 64. Secondary filtrate line 64 then communicates with discharge valve 74, and the secondary filtered fluid is discharged through discharge line 76 and/or discharged through alternate discharge line 78. Final discharge valves 82 may be placed downstream from the discharge lines.
As also shown in the FIG. 3, an outlet diversion valve 72 is provided that interconnects the secondary filter fluid line with the primary waste line 52 thereby providing additional fluid for washing/flushing of the primary waste line 52.
If it is desired to bypass the secondary filtration station and deliver the primary filtered fluid for re-use at the well cleaning operation, and then the secondary filter inlet valves 56 are closed. The coarsely or primary filtered fluid passing through line 54 then passes through bypass line 66 and secondary bypass valve 68 is opened, enabling the fluid to then pass through the secondary filtrate line 64.
If it is desired to use the primary filtered fluid to flush the primary waste line 52, then the secondary filter inlet valves 56 are closed, secondary waste valve 70 is opened, and the fluid flows through secondary waste line 51. Secondary waste line 51 connects to primary waste line 52.
The secondary filters also have a backwash capability in which the filters may be cleaned, and the concentrated contaminants can be evacuated for waste disposal. More specifically, when a backwash cycle occurs, the backwash liquid is discharged from the secondary filters 60 back through the three way secondary filter inlet valves 56 into the secondary waste line 51 thereby allowing the concentrated waste to be finally evacuated.
FIG. 3 shows the major portion of the filtration assembly being mounted on a piping skid 80. As discussed below, the skid mounted filtration assembly is advantageous in allowing the assembly to be easily installed in and removed from the enclosure 160.
FIG. 3 also illustrates a basic control scheme including the master or main controller 200 that can be housed within the main control panel 174. It is one object of the invention to provide a comprehensive control scheme that allows unattended operation of the system. The control scheme as illustrated comprises various inputs including a first pressure reading 202 at the inlet of the primary filtration station, a downstream pressure reading 204 located just downstream from the primary filtration station, and another downstream pressure reading 206 located just downstream from the secondary filtration station. The pressure reading 204 is also used as the inlet pressure reading for the secondary filtration station. The control scheme in the FIG. 3 also illustrates two flow monitors, one flow monitor 208 positioned to measure fluid flow within the secondary filtered fluid line 64, and another flow monitor 210 located to measure fluid flow within the primary waste line 52. The pressures recorded at these designated locations, along with the flow rates measured, enables a software/firmware application in the controller 200 to monitor the desirable flow of liquid through the filtration assembly. The control scheme also includes various outputs to include solenoids or other electrical or pneumatic actuators to open, close and otherwise modulate the position of the valves in order to achieve a desired sequence of continuous filtration, backwash cycling, flushing of the waste lines, etc. Selected valves in the filtration assembly may be pressure sensing valves that are normally open under expected fluid pressure ranges, but then close upon sensed decreasing or increasing pressures past pre-determined upper and lower pressure trip points. These pressure sensing valves may also have signaling capability to serve as inputs to the controller 200 in which pressure specific information can be provided to the controller for purposes of monitoring overall filtration assembly operation and to provide timely maintenance or shutdown of the assembly in the event of valve failure. For example, a valve that becomes unseated in an overpressure situation could trigger a system shutdown to prevent a fluid spill, and/or the system could be programmed to also react by changing to a bypass operation mode in which incoming fluid for filtration bypasses the filtration assembly through the selected bypass lines thereby limiting amounts of fluid spillage. The control system is also capable of other functions such as automatic shutdown in the event of an alarm condition, and generating alarms such as gas and fire detection events. Manual and automatic emergency shutdown can be provided in the event of triggering alarm conditions. Some of the safety measures and remedial actions that can be incorporated in the system and which can also be monitored by the controller 200 include overpressure protection sensors on all filtration vessels, valves, fire and gas detectors, and pneumatic purge of all panels and habitable spaces in the event of the detection of high levels of volatile gases. Timers and various other sensors can be added to the control system to monitor the operation of the system. The system is intended to operate in classified hazardous environments, therefore the monitoring capabilities of the invention are provided to comply with regulations concerning operation of the system in such hazardous environments. The controller may also include communication elements such as a wireless interface that allows an operator to remotely control the system. Thus, the system can also be integrated within a communications system in which the software/firmware is web-based and allows remote operation and control of the system. Accordingly, it is also contemplated that the software/firmware provides a number of user interfaces that allows a user to view operation of the system and to send commands to modify operation of the system. Particularly advantageous user interfaces include those graphical user interfaces that provide a visual depiction of the system during operation and the various parameters measured by input devices incorporated in the system. Incorporation of the controller into a wireless communications system is ideal for operation of the system in remote locations.
FIG. 3 also illustrates a tank 92 that stores treatment chemical(s) to be added to the filtrate stream. A dosing pump 90 introduces treatment chemicals/conditioners through line 94 into the secondary filtrate line 64. The dosing pump meters a desired quantity of the chemicals/conditioners and the dosing pump can also be controlled by the master controller 200. Thus, the filtered fluid stream can be further conditioned/treated to meet the needs of the specific wellbore being cleaned. FIG. 3 illustrates the chemical tank and pump 90 being mounted on the skid/platform 80. FIG. 2 does not illustrate the tank and pump, but it shall be understood that the tank and pump could be mounted in a number of locations to include open floor space within the filter assembly room.
FIGS. 4-7 illustrate the filtration assembly 10 in a preferred embodiment. For clarity purposes, not all of the components labeled in the schematic diagram of FIG. 3 are labeled in FIGS. 4-7. Furthermore, some of the elements shown in the FIG. 3 are not also illustrated in FIGS. 4-7 to include valves 26, 82 and 84, pump 90, line 94, and chemical tank 92. Some or all of these elements not shown in FIGS. 4-7 can be mounted to the trailer/vehicle that carries the enclosure 160.
The filtration assembly 10 is preferably mounted on the piping skid or base 80 that allows the assembly to be easily manipulated as a single unit. Thus, the intention of the filtration assembly design is to provide a modular, integral unit that can be more easily installed, removed, repaired, and transported. FIGS. 4-7 also illustrate that the filtration assembly has a very narrow, linear profile in which the filtration assembly is especially adapted for fitting within the one room of the enclosure 160. More specifically, the filtration assembly is arranged so that the primary filter 36 extends along a longitudinal axis X-X. The secondary filters 60 extend vertically, and are spaced from one another in a linear fashion and substantially parallel to the axis. The filtrate lines, diversion lines, and waste lines are also oriented along or substantially parallel to the axis, thereby maintaining the relatively narrow profile along the axis. In the preferred embodiment, the pump 30 is arranged substantially perpendicular to the axis that enables both the inlet and discharge lines to be accessed along one of the longer sidewalls of the enclosure. However, this arrangement of the pump does not substantially alter the narrow, linear configuration of the filtration assembly, as the pump 30 occupies only a slightly greater amount of the piping skid 80 to which the filtration assembly is mounted. It should also be understood however that the pump 30 could be rotated 90 degrees so that it resides primarily under the primary filter 30 and, therefore, the discharge and inlet lines would extend parallel with the longitudinal axis.
FIGS. 4-7 do not illustrate a system of pipe hangers/supports; however, it shall be understood that the invention comprises a plurality of pipe supports in which the lower ends of the pipe supports are secured to the piping skid 80. In this manner, the pipe hangers are less intrusive in terms of occupying space since they are confined primarily to the profile of the skid, and the operator maintains the ability to access all sides of the filtration assembly without obstruction.
FIGS. 4-7 illustrate the valves 62 as being hand-operated as by inclusion of lever handles 63, while the remaining valves are illustrated without lever handles. It shall be understood that selected valves may be manually operated, or all of the valves may be automatically controlled by use of solenoids or other electrically or pneumatically controlled actuators.
Referring to FIG. 8, the enclosure 220 is illustrated in another embodiment. This enclosure is of the type that has access openings and doors for access to the interior of the enclosure that may be closed and sealed. The enclosure 220 includes a roof 222, sidewalls 224, and end walls 226. The side of the enclosure 220 illustrated in the elevation view of FIG. 8 shows dual filter room doors 228 that allow access to the filter room. The dual doors 228 allow for easy removal of the primary or secondary filters, or other components of the filtration system that may require cleaning or maintenance. Vertical handles 270 extend along the doors for easy handling of the doors 228. An access panel 230 is provided to gain access to the fluid fittings of one of the bulkhead supports 180. As mentioned, a bulkhead support 180 has one or more openings that receive the inlet/discharge lines from the filtration assembly. Three exterior lights 232, are shown, and these lights are mounted within corresponding recesses such that the lights do not protrude beyond the surface of the sidewalls 224. These exterior lights 232 can provide adequate lighting in low visibility times when the system is operating. One type of light that is particularly advantageous for the exterior lights 232 is the use of LED lights. LED lights have low power consumption and are ideal for use in extreme cold conditions. A light detecting sensor 248 is also shown which may be used to automatically turn on the exterior lights 232 when the triggering lighting conditions exist. Another access panel 242 is shown, namely, a shore power access panel 242. This panel 242 provides access to a power distribution panel (not shown) within the enclosure. In the event external or shore power is available, this panel allows an exterior power line (not shown) to be connected to the power distribution panel in the enclosure. A phase monitor light 249 is also shown that is used to alert operators when improper electrical phasing has been arranged. Improper phasing can also be incorporated as a warning indication and annunciated on the main control panel. The pumps of the system, for example, are a type of equipment that can be damaged with improper phasing in which a pump could run in reverse causing damage to the pump and other system components. FIG. 8 also shows an exhaust stack 238 for carrying away exhaust from the generator. The side of the enclosure 220 shown in FIG. 8 also illustrates a man door 252 for the generator room. This door 252 is large enough for an operator to easily enter and exit the generator room, and the store may include a lock (not shown) to restrict access. It should also be understood that all of the doors and access panels could have locks to restrict access as necessary. Another access panel 240 is shown that may provide access to a heating manifold communicating with heating ducts (not shown) for heating the interior space of the enclosure. An external heater (not shown) could be used to supplement heating of the interior space within the enclosure, and the heating line from the external heater would connect to the heating manifold by opening the access panel 240. The heat generated from the generator 176 can also be used to heat the interior space. One or more electrical power receptacles 244 may be mounted on the sidewall 224 for powering tools or other equipment. Power is provided to the receptacles 244 by the generator 176 through a power distribution panel (not shown) within the enclosure, such as the generator control panel 178 or a separate power distribution panel. One or more emergency stops 248 may also be located on the exterior of the enclosure so that operators may shut down the system, or selected components of the system in the event of an emergency. For example, for a fluid spill or fire, it is advantageous to have an emergency stop located on the exterior of the enclosure so that an operator can immediately shut down the system or components without having to enter the enclosure. A marking panel or display 250 is shown that may be used to identify the particular enclosure, and to otherwise post information regarding the location where the system is operating, along with any necessary emergency instructions or warnings. A window 254 is shown, allowing at least some natural light to enter the filter room if the various access doors are otherwise closed, and also providing external viewing for operators within the filter room. The windows also help to prevent interference accidents for operators coming in and out of the enclosure at the same time. Another access panel 256 is shown, namely, an oil filter access panel that enables changing of the oil filter of the generator from the outside of the enclosure. As one can appreciate, there is likely limited space available within the generator room, and therefore, providing the access panel 256 allows for easy changing of the generator oil filter outside of the generator room.
Referring to FIG. 9, the other side of the enclosure 220 is illustrated. This side also has the exterior lights 232, an emergency stop 246, and a window 254. The window 254 shown in FIG. 9 is a window for the filter room. FIG. 9 also shows dual generator room doors 234, which are similar to the dual filter room doors 228. The generator room doors 234 also include louvers 236 mounted on the doors 234. The louvers 236 can be selectively opened or closed enabling outside air to enter the generator room. Control of the louvers can be achieved by the master or main controller 200. It may be desirable to allow outside air to enter the generator room in order to cool the generator room, or to evacuate the air within the generator room if it becomes filled with the exhaust. The louvers 236 may also come equipped with external hoods that feature screens to minimize ingress of birds, insects or other wildlife, and precipitation. Accordingly, the louvers can be operated for controlled airflow but avoiding interior damage or contamination of the enclosure. The protective hoods are particularly useful in allowing the louvers to remain open and the system operating even in blizzard conditions. Door 258 is a man door for access to the filter room, and this door may also have a lock to restrict entry. FIG. 9 also illustrates another optional marking panel 260 that can be used to selectively label or mark the enclosure, such as regarding the type of hazardous materials that may be found within the enclosure.
Referring to FIGS. 10 and 11, the respective ends of the enclosure 220 are illustrated. Both ends of the enclosure include end panel doors 262 mounted to the end walls 226. Each of the doors has vertical door handles 270 for easy grasping of the doors. The end of the enclosure 220 shown in FIG. 10 is the end adjacent the generator room. This Figure also shows louvers 266 mounted on one of the doors 262. The louvers 266 are also controlled by the master or main controller 200 in the same manner as louvers 236 mounted on doors 234. Additional exterior lights are also illustrated, namely, exterior lights 264 mounted above the doors 262. Like the exterior lights 232, the exterior lights 264 may be mounted within respective cavities or recesses, which therefore protect the lights 264. Retractable footsteps (not shown) can be provided at the man doors or end panel doors to accommodate entry.
From a review of the second embodiment of the enclosure 220 shown in FIGS. 8-11, enhanced functionality is provided on the enclosure for not only controlling access to the interior space within the enclosure, but also providing additional functions such as the emergency stops 246 and receptacles 244. Each of the access panels and doors may include peripheral sealing gaskets, weather-stripping seals, or other insulating means so that the interior space within the enclosure is effectively isolated from exterior weather conditions when the access panels and doors are closed.
The advantages of the present invention are apparent. A compact, automated, transportable, and self-sufficient re-circulation and filtration system is provided. The system is automated and allows the system to run unattended for significant periods of time. This system can be mounted to a trailer or hauling vehicle platform that is not over-sized, which greatly eases transporting requirements by not requiring any special transportation permits. The enclosure provides a habitable space for operators to efficiently inspect, troubleshoot, and repair the system. The enclosure can be insulated for use in severe climatic conditions. Selected addition of chemicals/conditioners allows the system to not only handle removal of contaminants, but to also treat the cleaning fluid for a desired application. The enclosure can be towed, for example, by a vehicle which includes a coiled tubing dispenser. Thus, the system can also be considered in combination with a coiled tubing dispenser and therefore in another aspect of the invention, it includes the integrated fluid filtration and recirculation system along with a coiled tubing dispenser.
Although the system and method of the present invention have been provided in preferred embodiments, it shall be understood that various other changes and modifications can be made to the invention commensurate with the scope of the claims appended hereto.

Claims

What is claimed is:

1. An integrated fluid filtration and recirculation system comprising:

an enclosure having at least two rooms, said enclosure comprising a main pallet forming a floor, sidewalls, and a roof;

a first door for accessing one room, and a second door for accessing the other room;

an electrical power generator located in one room;

a filtration assembly located in the other room, said filtration assembly comprising:

a primary filtration station;

a secondary filtration station;

a plurality of filtrate lines;

a plurality of bypass lines;

a plurality of waste lines;

wherein said filtration assembly is arranged for primary and secondary filtration of a liquid stream passing through the assembly to create a filtered liquid stream;

at least one filtration pump for conveying said fluid through said filtration assembly; and

a main controller for providing automated control of said electrical power generator and said filtration assembly.

2. A system, as claimed in claim 1, wherein:

said filtration assembly is generally aligned along a longitudinal axis thereby minimizing a profile of said filtration assembly, at least said primary filtration station and said secondary filtration station being linearly aligned to minimize the profile.

3. A system, as claimed in claim 1, wherein:

said main controller receives pressure and flow inputs based on measured parameters of operation of said filtration assembly, and said main controller provides outputs including signals to control a plurality of valves incorporated in said filtration assembly which dictate flow paths and volumes of the liquid flowing through the assembly.

4. A system, as claimed in claim 1, further including:

a dosing pump for supplying an amount of a treatment chemical to the filtered liquid stream.

5. A system, as claimed in claim 1, further including:

an inlet line for receiving fluid to be filtered by said filtration assembly, and a discharge line for conveying filtered fluid away from the system;

a bulkhead support for mounting a location at which said inlet and outlet lines pass through said enclosure; and

an access panel for accessing said bulkhead support.

6. A system, as claimed in claim 1, further including:

at least one exterior light mounted on said enclosure.

7. A system, as claimed in claim 1, further including:

at least one set of dual access doors mounted on one sidewall of said enclosure for accessing at least one of said rooms.

8. A system, as claimed in claim 7, wherein:

said set of dual access doors are generator room access doors: and louvers mounted on said generator room access doors for allowing outside air to enter the generator room, wherein said main controller provides control for selectively opening and closing said louvers.

9. A system, as claimed in claim 1, further including:

a generator exhaust stack connected to an exhaust line of said generator, said exhaust stack extending through said roof for carrying exhaust fumes away from said enclosure.

10. A system, as claimed in claim 1, further including:

a power receptacle mounted on said sidewall for providing power external to said enclosure.

11. A system, as claimed in claim 1, further including:

a shore power access panel mounted to one of said sidewalls enabling an external power line to be connected to said enclosure.

12. A system, as claimed in claim 1, further including:

an emergency stop mounted to one of said sidewalls of said enclosure allowing an operator to shut down said system or selected components of said system in the event of an emergency.

13. A system, as claimed in claim 1, further including:

a window mounted to one of said sidewalls.

14. A system, as claimed in claim 1, further including:

an oil filter access panel mounted to one of said sidewalls enabling exterior access to an oil filter of said generator.

15. A system, as claimed in claim 1, wherein:

said sidewalls include opposing end walls, and one set of dual access doors being mounted on at least one of said end walls for accessing at least one of said rooms.

16. A system, as claimed in claim 15, further including:

louvers mounted on said dual access doors for allowing outside air to enter the corresponding room, wherein said main controller provides control for selectively opening and closing said louvers.

17. In combination, a system for cleaning a wellbore, said system comprising:

a coiled tubing dispenser and an amount of coiled tubing dispensed from said coiled tubing dispenser and placed down-hole in said wellbore;

an integrated fluid filtration and recirculation system comprising:

an enclosure comprising a main pallet forming a floor, sidewalls, and a roof, an interior of said enclosure separated into two rooms by a fire rated dividing wall;

an electrical power generator mounted in said enclosure;

a filtration assembly mounted in said enclosure for filtering cleaning fluid placed down-hole;

said filtration assembly including a primary filtration station and a secondary filtration station;

at least one filtration pump mounted in said enclosure for conveying said cleaning fluid through said filtration assembly to filter said cleaning fluid;

a main controller mounted in said enclosure for providing automated control of the electrical power generator and filtration assembly;

a fluid transport line interconnecting filtered cleaning fluid from said filtration assembly to said coiled tubing; and

a return line communication with said wellbore for returning used cleaning fluid from the wellbore to said filtration assembly.

18. The combination, as claimed in claim 17, wherein:

said enclosure further includes climate controlled elements for controlling the temperature within said enclosure, said climate control elements including at least one of a heater and an air conditioner.

19. The combination, as claimed in claim 17, wherein:

a main controller is incorporated within wireless communication system, said main controller producing user interfaces that show operating parameters of said generator and said filtration assembly, and said user interfaces further providing command options for commands to be sent by the user to the main controller for controlling the operation of the generator and filtration assembly remotely.

20. The combination, as claimed in claim 17, wherein:

21. The combination, as claimed in claim 17, wherein:

22. A system, as claimed in claim 17, further including:

an access panel for accessing said bulkhead support.

23. A system, as claimed in claim 17, further including:

at least one exterior light mounted on said enclosure.

24. A system, as claimed in claim 17, further including:

25. A system, as claimed in claim 24, wherein:

said set of dual access doors are generator room access doors for accessing a generator room as one of said two rooms: and

louvers mounted on said generator room access doors for allowing outside air to enter the generator room, wherein said main controller provides control for selectively opening and closing said louvers.

26. A system, as claimed in claim 17, further including:

27. A system, as claimed in claim 17, further including:

28. A system, as claimed in claim 17, further including:

29. A system, as claimed in claim 17, further including:

30. A system, as claimed in claim 17, further including:

a window mounted to one of said sidewalls.

31. A system, as claimed in claim 1, further including:

32. A system, as claimed in claim 17, wherein:

33. An integrated fluid filtration and recirculation system comprising:

an electrical power generator located in one room;

a primary filtration station;

a secondary filtration station;

a plurality of filtrate lines;

a plurality of bypass lines;

a plurality of waste lines;

wherein said filtration assembly is arranged for primary and secondary filtration of a liquid stream passing through said assembly to create a filtered liquid stream;

at least one filtration pump for conveying said fluid through said filtration assembly;

a main controller for providing automated control of said electrical power generator and said filtration assembly; and