Modular downhole debris separating assemblies

A downhole system can include multiple sub-components of a downhole debris separator assembly that is modular. The system can also include multiple couplers arranged on or among the sub-components of the multiple sub-components. Each of the couplers can connect with others of the couplers in different combinations to form respectively different configurations of the downhole debris separator assembly.

TECHNICAL FIELD

The present disclosure relates generally to devices for use in a wellbore in a subterranean formation and, more particularly (although not necessarily exclusively), to modular assemblies for separating debris in a downhole environment.

BACKGROUND

Preparing a well system traversing a hydrocarbon bearing subterranean formation often involves running a string of tubular members (often individually called “tubulars” or “joints”) from surface into place in a wellbore. The string can be filled with fluid by permitting wellbore fluid to enter the string, e.g., via “auto-filling” equipment at a lower-most end of the string. The wellbore fluid can contain debris, such as from drilling or other operations. The debris can adversely affect the performance of the auto-fill equipment, which can necessitate filling from surface and the associated costs in time and resources. Additionally or alternatively, debris passing the auto-filling equipment can become trapped in the tubulars. The trapped debris can settle within the tubulars and form masses that can impede or hinder subsequent operations in the wellbore.

DETAILED DESCRIPTION

Certain aspects and examples of the present disclosure are directed to modular assemblies for separating debris in a downhole environment. The assemblies can separate debris from wellbore fluid, e.g., to prevent debris from reaching or adversely affecting components receiving the wellbore fluid. For example, the assemblies may be arranged within a tubular to reduce or eliminate an amount of debris that is carried by wellbore fluid and that might otherwise contaminate auto-fill equipment. The assemblies can be modular, e.g., formed from a number of individual components that can be fit together in different combinations, orders, or arrangements.

In various aspects, the debris separator assemblies are customizable as a result of the modular construction. For example, the debris separator may be scalable. The modular construction may allow components of the debris separator to be added, removed, or substituted, such as to increase or decrease an amount of debris separation provided. In one example, extra components can be removed or added at the ends of an assembly or between components in an assembly of the debris separator. This may allow the debris separator to be readily changed in size, for example, to accommodate a shorter available section of a tubular or to increase an amount of debris separation in response to conditions present in a particular well operation.

In various aspects, the modular construction allows the debris separator to be customizable in other respects. The modular construction can allow different types of components to be interchanged with one another. In some aspects, this may facilitate modifications in relative orientation of features of components. In an illustrative example, a component with one angular orientation may be replaced by a component with a different angular orientation as a result of both components being compatible with a particular coupler. In another illustrative example, an amount of space between a pair of components may be changed by substituting one or more intervening components with one or more other components having a different total size.

The modular construction may reduce costs associated with the debris separator. For example, making the debris separator from a large number of repeated smaller modular components may reduce a size, number, or complexity of manufacturing infrastructure used for production. Additionally, smaller components may be shipped or stored in smaller, less expensive and more easily manageable packages than a package large enough to accommodate an entire assembly. Furthermore, installation may be simplified by installing a number of smaller sub-assemblies in stages in lieu of installing a complete assembly in a single large unwieldy unit.

These illustrative examples are given to introduce the reader to the general subject matter discussed here and are not intended to limit the scope of the disclosed concepts. The following describes various additional aspects and examples with reference to the drawings, in which like numerals indicate like elements, and directional descriptions (e.g., “left,” “right”) are used to describe the illustrative aspects as they are depicted in the drawings. Like the illustrative aspects, the numerals and directional descriptions included in the following should not be used to limit the present disclosure.

FIG. 1illustrates an example of a well apparatus110having a debris separator device128. The well apparatus110may include a casing string112that is being lowered into a wellbore114formed through a hydrocarbon-bearing subterranean formation116. The debris separator device128may be positioned within a shoe track131of the casing string112. The well apparatus110may be lowered into a heel portion118of the wellbore114. The heel portion118may transition the wellbore114from a substantially vertically oriented section120of the wellbore114to a deviated (e.g., relatively horizontal or slanted) section122of the wellbore114.

Prior to the well apparatus110being lowered into the wellbore114, the wellbore114may have been drilled to a certain depth via a drill string that includes a drill bit. This previous drilling operation may have generated cuttings124or other debris from the drill bit cutting into the formation116to create the wellbore114. These cuttings124may be distributed in a layer across a lower wall126of the deviated section122of the wellbore114as the casing string112is being run into the well. In some aspects, the cuttings124are additionally or alternatively suspended or otherwise carried by mud or other fluid within the wellbore114.

The debris separator device128may separate cuttings124from mud flowing through the well apparatus110as the casing string112runs to depth. The debris separator device128may be run in with the casing string112, e.g., at the bottom of the well apparatus110. For example, the debris separator device128may form the bottom forty feet (or other amount) of the well apparatus110lowered into the wellbore114.

In various aspects, the well apparatus110may facilitate auto-fill operations while the casing string112is being lowered. The auto-fill operations enable downhole fluid (e.g., mud) to flow up through the well apparatus110as the casing string112is being lowered. This may allow the casing string112to be run in to the wellbore114without a surface-mounted hydraulic pump being used to circulate fluid through the wellbore114. Instead, as the casing string112is pushed downward through the wellbore114, the mud may enter via a float shoe130of the well apparatus110, as shown by arrow132. This flow may be created as a result of running the well apparatus110into the wellbore114filled with mud and cuttings124. The mud may continue to flow through the debris separator device128, through a float collar134, and into the casing string112.

When performing a subsequent cementing operation, the well apparatus110may push cement downward through the casing string112, float collar134, debris separator device128, and float shoe130, and into an annulus136between the well apparatus110and the wellbore114. The cement may push the mud back out of the casing string112. The float collar134may include check valves that can facilitate a one-way flow of fluid and cement through the float collar134during the cementing operation. When operating as desired, the check valves close to prevent cement from creeping or flowing back up the casing string112. This may allow the cement to set up in the annulus136, thereby completing the cementing job. When the cementing job is completed, the debris separator device128and the float shoe130may also be filled with cement. From this point, the well may be completed or another drilling tool may be lowered to drill out the end of the well apparatus110.

The debris separator device128may be used to capture and control the amount of cuttings124that flow into the well apparatus110with the mud as the well apparatus110is lowered. For example, the debris separator device128may keep the cuttings124from interfering with operation of the float collar134. Specifically, if the cuttings124were to interfere with the check valve of the float collar134, the check valve might fail to close after cement is run into the wellbore114, thereby compromising the ability of the cement to flow into and properly set in the bottom of the well apparatus110. To prevent this from happening, the debris separator device128in some aspects may be used to capture and periodically flush out cuttings124that enter the well apparatus110before the cuttings124reach the float collar134.

In addition, the debris separator device128may capture and maintain the cuttings124in designated pockets of the debris separator device128while leaving a flow path open through designated conduits. This may prevent the cuttings124from bridging at the float collar134. The term “bridging” refers to a large amount of cuttings124that might gather uphole of the check valve in the float collar134and act as a barrier that filters larger solids out of the cement mixture during the cementing process. In effect, this bridging may filter the cement so that a more watery cement substance than desired is output into the annulus136of the wellbore114. As described in detail below, the debris separator device128may include various structures that capture and retain the cuttings124, in order to prevent the occurrence of such bridging.

WhileFIG. 1depicts the well apparatus110as being arranged in the heel portion118of a horizontally oriented wellbore114, the well apparatus110may be equally arranged in a vertical or slanted portion of the wellbore114, or any other angular configuration, without departing from the scope of the disclosure. Additionally, the well apparatus110may be arranged along other portions of the deviated section122of the wellbore114in order to secure the casing string112within a portion of the wellbore114without the interference of cuttings124and other particles entering the casing string112. Furthermore, in some aspects, the debris separator device128may be used in other tubulars in addition to or as alternatives to the casing string112.

In various aspects, the debris separator device128is modular in construction. This may allow the debris separator device128to be formed from a set of modules or sub-components (collectively termed “components” herein for ease of reference) that can be arranged together in different combinations, such as in different quantities, orders, orientations, or arrangements. The components can be arranged or coupled together so as to interact with one another and cause separation of debris from fluid flowing through the debris separator device128. Such modular construction can allow greater flexibility for operations involving the debris separator device128and can reduce complexity or costs of manufacture, shipping, or installation of the debris separator device128.

Components of the set may couple with one another to form sub-assemblies. In some aspects, the components may couple by directly connecting to one another. Additionally or alternatively, the components may couple indirectly, such as by two components each being coupled with a common object or through intervening structure. In one example, two components are arranged in series in a tubular to provide the function of the debris separator device128and are each coupled with the tubular, yet spaced apart therein so as to not be directly connected to one another.

The components of the debris separator device128can be coupled together by any suitable coupler or method of coupling. In some aspects, the debris separator device128may be modular as a result of couplers being compatible with multiple components or types of components. This may allow components of the debris separator device128to be interchangeable with respect to an individual coupler. In some aspects, modularity may be a result of each coupler being alternatively connectable with couplers of other components of the set of modular components. Non-limiting examples of suitable couplers include snap-together pieces, threaded components, pieces that are pinned in place; pieces that are glued or otherwise bonded together, and slip fitting one piece over another.

The debris separator device128may separate debris from flowing fluid in a variety of ways. The particular components combined to form the debris separator device128can determine how debris is separated. In some aspects, components (e.g., screens) obstruct particles and allow passage of fluid flow. In some aspects, components (e.g., impellers) affect fluid flow characteristics and cause particles to move out of the flow, e.g., away from designated conduits or into designated pockets. Components may include any combination of structure that facilitates component coupling, structure that defines a fluid path, and structure that removes particles out of a defined fluid path (e.g., directs particles away from the path or blocks particles from traveling along the path).

Different types of debris separator devices128can be used in the well apparatus110depicted inFIG. 1. The debris separator device128may include, but is not limited to, components that utilize any of the debris separating techniques or coupling techniques described in the following examples.

Example #1: Separating by Angularly Offset Pass-Through Areas

FIGS. 2-5illustrate one example of a debris separator device200. The debris separator device200can include plates202with pass-through areas208. The pass-through areas208of the plates202can be angularly offset from one another or otherwise arranged to separate debris from fluid passing through the debris separator device200. The debris separator device200can be modular by including snap-fitting sections of a mandrel206or other features that allow the plates202to be readily added, subtracted, or substituted to change the operation of the debris separator device200.

FIG. 2is a perspective cutaway view of the debris separator device200according to some aspects. The plates202(e.g.,202A,202B, etc.) of the debris separator device200can be positioned within a tubular member204. In some aspects, the tubular member204can form part of a casing string, such as the casing string112inFIG. 1. In other aspects, the tubular member204may be inserted in to a casing string112having an internal diameter that is larger than an external diameter of the tubular member204.

A plate202can include a corresponding pass-through area208(e.g.,208A,208B, etc.). The pass-through area208can be an opening of sufficient size to allow fluid carrying particulate or debris to flow from a one side of the plate202to another, opposite side of the plate. In some aspects, the pass-through area208is positioned near an end or edge of a plate202. As examples, the pass-through area208can be formed as a passage through the plate202(such as shown inFIG. 2) or as a gap between an edge of the plate202and an interior surface of the tubular member204.

The pass-through area208can be positioned radially from a central axis of the tubular member204. The plates202can be arranged such that pass-through areas208of adjacent plates202are positioned at different angular positions within the tubular member204. The pass-through areas208can be angularly offset from one another. For example, the plates202can be arranged so that proximate pass-through areas208alternate between bordering a top of the tubular member and bordering a bottom of the tubular member (e.g., offset from one another by 180 degrees), as shown inFIG. 2.

Pass-through areas208additionally or alternatively can be offset from one another by any other suitable amount or angular increment, and are not limited to an offset of 180 degrees. In some aspects, offsets of less than 180 degrees (e.g., 120 degrees) can reduce a sensitivity of the debris separator device200to the direction of gravity. For example, the arrangement of the debris separator device200can improve the likelihood that at least one pass-through area208may be oriented toward the direction of gravity. This can facilitate a greater degree of settling of particles due to gravity in between the plates202. Additionally, although a uniform offset between each pass-through area208is shown inFIG. 2, the offset between one pass-through area208and an immediately succeeding pass-through area208may differ from the offset between the pass-through area208and an immediately preceding pass-through area208. Furthermore, although plates202and pass-through areas208are depicted inFIG. 2as uniform features, these features may also vary from one another in size, shape, thickness, and orientation.

The plates202can be supported by a support structure, such as a mandrel206. The manner or orientation in which the plates202are coupled with the mandrel206can determine a relative orientation of the plates202to one another. The relative arrangement of the plates202can align features of the plates202to reduce an amount of fluid-borne particulate that can pass through the debris separator device200.

The plates202can be angled relative to a length of the tubular member204. For example, the plates202can be tilted from a position perpendicular to a length of the tubular member204. Any plate202can span an elongate or longitudinal section of the bore of the tubular member204. One or more of the plates202can be elliptically shaped, which can facilitate the plate202spanning an elongate or longitudinal section of the bore of the tubular member204. Although the plates202shown inFIG. 2are elliptically shaped, in other embodiments, the plates202are circularly shaped to match a circular bore shape of the tubular member204.

In some aspects, the plates202can be angled in an alternating manner along a length of the tubular member204. For example, the plates202may alternate an angle of tilt so that adjacent plates202form a V-shape. In one illustrative example, a first plate202A can have a top side228A tilted forward from a perpendicular position and toward a first end211of the tubular member204, while a second adjacent plate can have a top side228B tilted backward from a perpendicular position and away from the first end211of the tubular member204. The bottom sides230A,230B of the plates202A,202B can be adjacent to one another to form a point of the V-shape. In some aspects, the bottom sides230A,230B are spaced apart and not immediately adjacent one another. Although the plates202shown inFIG. 2are angled relative to one another, in some aspects, the plates202may be parallel to one another.

In some aspects, at least some of the plates202include a screened section having perforations210through the plates202. The perforations210can be sized to permit the passage of fluid through the plates202, yet block passage of particulate carried by the fluid. A screened section can be formed in a plate202in any suitable manner, including, but not limited to, making perforations210directly in the plate202or stretching a mesh defining the perforations210across an open portion of the plate202. A screened section can include any suitable number of perforations210. In some aspects, perforations210substantially cover an entire area of the plate202not occupied by the pass-through area208. In some aspects, smaller portions of the plate202include one or more screened sections with perforations210.

FIG. 3is a side cutaway view of the debris separator device200, showing an example of fluid and particulate flow in a first direction according to certain aspects. Fluid can enter a first side211of the tubular member204(e.g., the right end inFIG. 3), as depicted by arrows212inFIG. 3. For example, the tubular member204can be moved within a wellbore114in a direction depicted to the right inFIG. 3, causing a flow in the leftward direction ofFIG. 3. The fluid alternatively or additionally can be directed into the first end211of the tubular member204by auto-fill equipment or the like. The fluid entering the first end211of the tubular member204can convey particulate, including individual particles216(depicted in an enlarged manner for ease of visibility). The mandrel206can have closed ends, preventing passage of fluid through the mandrel206.

A first plate202A in the debris separator device200can be tilted. The tilt may angle the pass-through area208A of the first plate202A toward the first end211of the tubular member204. The tilt may also angle an opposite closed end209A of the first plate202A away from the first end211. Angling the first plate202A in this manner can form a ramp along the first plate202A toward a corner214A formed between an edge of the first plate202A and an interior surface of the tubular member204.

In some aspects, particles216encountering a plate202can be moved along an angle of the plate202by fluid flow. For example, the fluid entering the tubular member204from the first end211can push particles216along the ramp formed by the angled first plate202A, such as illustrated by arrow236. The particles216can be moved along the angled first plate202A toward the corner214A (or pocket) formed between an edge of the first plate202A and an interior surface of the tubular member204. Moving particles216toward the corner214A can clear particles216from perforations210A, if present. Clearing the perforations210can allow additional fluid to travel through perforations210A in the first plate202A (as depicted by arrow222A) and increase an amount of particles216that are screened out of the fluid.

A next plate202B in the series in the debris separator device200can be tilted at a different angle relative to the bore of the tubular member204. The second plate202B can be tilted so that the second pass-through area208B is tilted toward the source of fluid flow (e.g., toward the first end of the tubular member204) and so that the closed end209B forming a corner214B is tilted away from the source of fluid flow. This may longitudinally align corner214B or the closed end209B (or both) with the pass-through area208A. Altering the tilt of plates202along with the angular position of the pass-through areas208can allow particles216to be consistently pushed toward corners214and away from pass-through areas208. For example, some particles216may pass through the pass-through area208A instead of being directed along the angled first plate202A toward the corner214A. These particles passing through the pass-through area208A can be directed by a longitudinal flow of fluid toward the corner214B that is longitudinally aligned with the pass-through area208A, such as illustrated by arrows238.

If perforations210of a plate202are omitted or become blocked by accumulated particles216, fluid laden with particles216can still pass through the pass-through area208of the plate202. For example, fluid coming from the first end of the tubular member204as depicted by arrows212can pass through the pass-through area208A (as depicted by arrow218) even if perforations210A are blocked or omitted. If perforations210B are also blocked or omitted, the fluid may travel along a fluid path between the pass-through area208A and pass-through area208B.

The offset between the pass-through area208A and pass-through area208B can provide a tortuous path for the fluid flow. Direction changes from the tortuous path can remove particles216from the fluid passing through the debris separator device200. For example, the particles216can be carried by momentum against a first plate202A and dropped while the fluid changes direction between adjacent pass-through areas208A,208B that are offset from one another. In another example, the changes of direction from the tortuous path can reduce a speed of the fluid flow, thereby increasing a number of particles216that can drop or settle out of the fluid under the effects of gravity.

In some aspects, the tortuous path additionally or alternatively can yield other benefits. For example, routing cement through the tortuous path of the debris separator device200during a cementing operation may provide additional mixing for the cement and improve the quality of the cementing operation or the overall displacement efficiency of a section of a casing string112having the debris separator device200.

FIG. 4is a side cutaway view of the debris separator device200, showing an example of flow in a second direction according to some aspects. Fluid can enter from a second end213, such as shown by arrow224. The fluid entering from the second end213can include fewer particles216than fluid entering the debris separator device200from the first end211(such as the fluid discussed above with respect to the arrow212ofFIG. 2). As examples, the fluid entering from the second end213may include fewer particles216as a result of having passed through debris separator device200, as a result of being introduced from a surface of the wellbore114, or both. The fluid entering from the second end213can flush particles216out of the debris separator device200and prepare the debris separator device200for additional operations.

Fluid flow through perforations210C can dislodge particles216accumulated in the corner214between the plate202C and the tubular member204. Fluid flow from the second end213of the debris separator device200can direct the particles216towards a next plate202B along the length of the debris separator device200, as shown by arrow242. Particles reaching the next plate202B can be directed along the angle of the plate202B toward the pass-through area208B (as shown by arrow232) and pass through the pass-through area208B (as shown by arrow246).

When fluid flows from the second end213of the debris separator device200along the plates202, the pass-through areas208are angled away from the source of fluid, while the closed end209of the plate is oriented toward the source of fluid. This can provide a ramp for urging particles toward the pass-through area208. The particles can thus be sequentially pushed through pass-through areas208and pushed out of the debris separator device200, as shown by arrow248. Additionally, the angle can direct the particles216away from perforations210B, as shown by arrow232. This can clear the perforations210B and permit additional fluid to flow through and dislodge additional particles previously trapped by the perforations210B, as illustrated by arrows244.

FIG. 5is an exploded view of examples of components of the debris separator device200according to some aspects. The debris separator device200shown inFIG. 5includes mandrel sections206(e.g.,206A,206B, etc.), plates202(e.g.,202A,202B, etc.), and end caps278,279. The components are shown inFIG. 5in a configuration to provide offsets of 120 degrees, in contrast to the offsets of 180 degrees shown inFIGS. 2-4.

The debris separator device200shown inFIG. 5includes couplers (e.g., protrusions262, openings266, and collars264) that facilitate a modular construction and connect components together. For example, a first mandrel section206A can couple with a first plate202A. The first mandrel section206A can include a first protrusion262A extending from one end. The first plate202A can be translated onto the first protrusion262A, such along line272. The first protrusion262A can extend through a central opening266A (or opening266A positioned other than centrally) of the first plate202A for supporting the first plate202A relative to the first mandrel section206A. The first mandrel section206A can also include an aligning feature so that the first plate202A aligns in a particular orientation relative to the first mandrel section206A. The aligning feature shown inFIG. 5is a key268that can be inserted into a corresponding slot270in the first plate202A; however other aligning features may be used. In some aspects, the key268may be an insertable pin (e.g., a bolt, screw, rivet, clip, hinge, or the like) that slides (e.g., from the position of the key268in phantom line inFIG. 5to the position of the key268in solid line inFIG. 5) through the slot270and into engagement into the first protrusion262A to secure the first plate202A in place. The first protrusion262A may include a first angled face284, which may determine a tilt of the first plate202A within the completed subassembly.

Other plates202may include similar features to the first plate202A, which may allow any of the plates202of the debris separator device200to be coupled with the first mandrel section206A, e.g., to change the order of plates202, to change a type of plate202utilized, or to facilitate another modular change.

The first mandrel section206A can also couple with a second mandrel section206B. The first plate202A may be secured in between the first mandrel section206A and the second mandrel section206B. The second mandrel section206B may include a collar264that can be installed over the first protrusion262A of the first mandrel section206A. The collar264may fit over a portion of the first protrusion262A extending through the first plate202A (e.g., along line272). The first protrusion262A can include prongs280that extend through the collar264. The prongs280can include barbs282that engage the collar264. The barbs282may deflect and snap into place in response to the protrusion262being moved a sufficient distance through the collar264. The second mandrel section206B may include a second angled face286that matches the first angled face284of the first mandrel section206A. This may limit a number of orientations at which the first mandrel section206A can couple with the second mandrel section206B, which may simplify installation by preventing coupling in a way other than intended. Alternatively or additionally, the prongs280may extend different lengths from the first angled face284so as to match different widths of the collar264along the second angled face286.

Other mandrel sections206(including the first mandrel section206A and the second mandrel section206B) may include features similar to the features just described for the first mandrel section206A and the second mandrel section206B. This may allow any of the mandrel sections206to couple with any other of the mandrel sections206or with any of the plates202in the debris separator device200, e.g., allowing additional modularity.

In some aspects, a mandrel section206can include a notch260. The notch260can extend through the mandrel section206transverse to a length of the mandrel section206. A bar or other leverage-providing component can be inserted into the notch260to provide a pushing surface by which a person can join the mandrel section206with another component of the debris separator device200.

Any of the mandrel sections206may couple with an end cap278,279. A top or first end cap278may include a protrusion (similar to the protrusion262) that can be received in a collar264of a mandrel section206. A bottom or second end cap279may include a collar (similar to the collar264) that can be received on a protrusion262of a mandrel section206. Any of the end caps278,279may include features (such as the key268or other aligning features) for coupling with plates202. The end caps278,279may be sized so as to be larger than openings through restrictions in a casing string112, such as to prevent mandrel sections206or protrusions262from passing through such openings and reaching or damaging auto-fill or other equipment.

Example #2: Separating by Longitudinally Offset, Partial Screens

FIGS. 6-9illustrate another example of a debris separator device600. The debris separator device600can include screens602. The screens602can cover different cross-sectional areas and be longitudinally offset from one another to separate debris from fluid passing through the debris separator device600. The debris separator device600can be modular by including threaded surfaces611,613(or other features) that allow sections with the screens602to be readily added, subtracted, or substituted to change the operation of the debris separator device600.

FIG. 6is a perspective cutaway view of the debris separator device600according to some aspects. The debris separator device600can include screens602(e.g., a first screen602A, a second screen602B, a third screen602C, and a fourth screen602D). The screens602can be positioned within a tubular member606. The screens602can include openings sized to permit the passage of fluid through the screens, yet block passage of particulate carried by fluid flowing through the debris separator device600. The tubular member606can be divided into sections612(e.g., a first section612A, a second section612B, a third section612C, and a fourth section612D). The sections612shown inFIG. 6are coupled by threaded surfaces611,613. Other couplers, however, can also be used. Each section612can correspond to a respective screen602. Each respective screen602can be coupled with the respective section612by any suitable coupler. In some aspects, the tubular member606can form part of a tubing string, such as the casing string112inFIG. 1. In some aspects, the tubular member606may be inserted in to a casing string112having an internal diameter that is larger than an external diameter of tubular member606.

The screens602can be longitudinally offset from one another in the tubular member606. For example, a first screen602A positioned in a first section612A can be closer to a first end608of the tubular member606than a second screen602B positioned in a second section612B.

The screens602can cover different portions of a cross-sectional area of the tubular member606. The different portions may collectively cover an entirety of the cross-sectional area. An example is provided with reference toFIGS. 7-8.FIG. 7is an end view of the first screen602A of the debris separator device600according to some aspects.FIG. 8is an end view of the second screen602B of the debris separator device600according to some aspects.

The first screen602A (FIG. 7) can have an annular shape between an interior edge of the tubular member606and a central area614of the cross-sectional area of the tubular member606. The annular shape of the first screen602A can cover a peripheral area616of the cross-sectional area without covering the central area614of the cross-sectional area.

The second screen602B (FIG. 8) can have a round shape covering the central area614without covering the peripheral area616. The first screen602A and the second screen602B can thus collectively cover the entirety of the cross-sectional area of the tubular member606. Collectively covering the entirety of the cross-sectional area of the tubular member606with screens602can reduce an amount of particles that may be carried through the debris separator device600.

Although the entirety of the cross-sectional area of the tubular member606can be covered by a first screen602A and a second screen602B covering opposite portions of the cross-sectional area of the tubular member606as just described, other arrangements are possible. For example, the entirety of the cross-sectional area may be covered by a group of two, three, or more screens of complimentary shapes. A shape of one screen may be larger than an area not covered by another screen such that a portion of the cross-sectional area is covered multiple times where the shapes overlap.

The first screen602A (FIG. 7) and the second screen602B (FIG. 8) can each cover less than an entirety of the cross-sectional area of the tubular member606. For example, the shape of the first screen602A (FIG. 7) can leave the central area614uncovered, while the shape of the second screen602B (FIG. 8) may leave the peripheral area616uncovered. Leaving at least a portion of the cross-sectional area of the tubular member606uncovered by a particular screen602can permit fluid to flow past the particular screen602when the particular screen602is blocked by particles.

Referring again toFIG. 6, the first screen602A can include a first rim618A. The first rim618A can extend away from the first screen602A and toward the first end608of the tubular member606. In some aspects, the first rim618A can be a tube. The first rim618A can be positioned at a boundary of the portion of the cross-sectional area of the tubular member606covered by the first screen602A. For example, the first rim618A can be positioned at a boundary between the peripheral area616and the central area614(such as shown in bothFIGS. 6 and 7). The first rim618A can be sized to prevent particulate caught in the peripheral area616by the first screen602A from crossing the boundary into the central area614and flowing past the first screen602A. For example, the first rim618A can extend toward the first end608of the tubular member606a sufficient amount to prevent particles from being swept from the first screen602A and through the central area614by fluid flowing from the first end608.

The second screen602B can include a second rim618B. The second rim618B can extend away from the second screen602B and toward the first end608of the tubular member606. In some aspects, the second rim618B can be a tube. The second rim618B can be positioned at a boundary of the portion of the cross-sectional area of the tubular member606covered by the second screen602B. For example, the second rim618B can be positioned at a boundary between the central area614and the peripheral area616(such as shown inFIGS. 6 and 8). The second rim618B can be sized to prevent particulate caught in the central area614by the second screen602B from crossing the boundary into the peripheral area616and flowing past the second screen602B. For example, the second rim618B can extend toward the first end608of the tubular member606a sufficient amount to prevent particles from being swept from the second screen602B and through the peripheral area616by fluid flowing from the first end608.

In some aspects, the second rim618B may be supported relative to the tubular member606by one or more flanges622B (e.g.,FIGS. 6 and 8). The second screen602B may be supported relative to the tubular member606by the second rim618B. In some aspects, the first screen602A may be supported relative to the tubular member606by coupling with an interior edge of the tubular member606(e.g.,FIG. 6-7). The first rim618A may be supported relative to the tubular member606by the first screen602A. In some aspects, the first rim618A additionally or alternatively may be supported by flanges similar to the flanges622B, although not shown inFIGS. 6-8. Flanges, screens, rims, and sections may be coupled with one another by any suitable coupler, including, but not limited to bonding or clipping.

FIG. 9is a side cutaway view of the debris separator device600according to some aspects. In some aspects, the first rim618A separates flow paths626A,628A through the first section612A of the tubular member606. For example, fluid flowing from the first end608of the tubular member606may encounter the first rim618A and be directed through a first flow path626A and a second flow path628A. The first screen602A can be positioned in the first flow path626A. For example, the first screen602A can cover an entirety of a cross-section of the first flow path626A. The first screen602A may prevent some particles carried by the fluid from passing the first section612A or otherwise function as a pocket to capture particles.

The second flow path628A of the first section612A may be less screened than the first flow path626A. For example, the first screen602A may cover the second flow path628A a negligible amount and permit particles to flow through the second flow path628A without much, if any, screening. Fluid directed through the second flow path628A of the first section612A may carry at least some particles through the first section612A and into the second section612B.

The second rim618B can separate the second section612B into another first flow path626B and another second flow path628B. The second screen602B can be positioned in the second flow path628B of the second section612B.

In some aspects, the first rim618A and the second rim618B are longitudinally aligned. Longitudinally aligning the first rim618A and the second rim618B may align flow paths of the first section612A and the second section612B for longitudinal fluid flow through at least one screen602. For example, fluid can flow through the first flow paths626A,626B and the first screen602A (such as depicted by the arrows630A and630B) or through the second flow paths628A,628B and the second screen602B (such as depicted by the arrows632A and632B).

In some aspects, the first rim618A and the second rim618B are longitudinally offset. For example, a longitudinal gap634may be positioned between the first rim618A and the second rim618B. Longitudinally offsetting the first rim618A and the second rim618B can permit fluid to flow separately from aligned flow paths of the first section612A and the second section612B. For example, fluid can flow from the second flow path628A of the first section612A to the first flow path626B of the second section612B through a third flow path (such as the longitudinal gap634) without passing through the first screen602A or the second screen602B (such as depicted by the arrows632A and630B). Such a flow may permit fluid to continue traveling through the tubular member606when the screens602A,602B are blocked with particles.

In some aspects, particles captured by the screens602can be flushed by directing fluid toward the first end608of the tubular member606. For example, particles captured by the second screen602B can be carried out through the second flow path628B in the second section612B and the aligned second flow path628A of the first section612A (such as opposite the arrows632B,632A). Particles carried through the first flow path626B of the second section612B can pass through the gap634and out through the second flow path628A of the first section612A (such as opposite the arrows630B,632A). The first rim618A can include a tapered portion620A tapering away from the first flow path626B of the second section612B and toward the second flow path628A of the first section612A. Such a tapered portion620A can direct flushed particles toward the open, unscreened second flow path628A of the first section612A. Similarly, the second rim618B can include a tapered portion620B that directs particles away from the screened second flow path628B (e.g., away from edges of the second screen602B) and toward the open and unscreened first flow path626B of the second section612B.

Example #3 Debris Separator Device with Weirs

FIGS. 10-13illustrate a further example of a debris separator device1000according to certain aspects. The debris separator device1000can include weirs1014(e.g., weirs1014A,1014B). The weirs1014can create a tortuous fluid flow to separate debris from fluid passing through the debris separator device1000. The debris separator device1000can be modular by including slots1110in weir plates1100, portions of inserts1302and1304that can be bonded together, coupling edges1310etc., or any other combination of features that allow assemblies with the weirs1014to be readily formed, added, subtracted, or substituted to change the operation debris separator device1000.

FIG. 10is a perspective cutaway view of the debris separator device1002according to some aspects. The debris separator device1002can be disposed in tubular member1004, e.g., in a portion of the casing string1012inFIG. 1. The debris separator device1002can include multiple weirs1014. The weirs1014can be positioned in multiple insert sections1006,1007,1008,1009,1010,1011,1012(e.g., insert sections1009,1010are shown as transparent so that weirs1014are visible). The insert sections1006-1012may be coupled in series by any suitable coupler.

The weirs1014can be oriented within the insert sections1006-1012, and the debris separator device1002as a whole, so as to selectively increase fluid velocity through the debris separator device1002. This may cause a solids slip velocity that separates solids from fluid within a desired section of the wellbore. In one example, the weirs1014are oriented such that a flow opening of a first weir1014A causes solids to deposit at a second weir1014A (if flow direction is from the first weir1014A to the second weir1014A) without obstructing a flow opening of the second weir1014B.

The weirs1014may be constructed from weir plates.FIG. 11depicts a front view of an example of a weir plate1100, in accordance with some aspects. The weir plate1100may comprise plastic, metal, a combination thereof, or the like. In at least one aspect, the weir plate1100comprises a semipermeable material, such as a mesh material. The weir plate1100can be dimensioned so as to fit within a weir assembly (such as debris separator device1002ofFIG. 10). The weir plate1100can include edges1102,1103,1104dimensioned to come in contact with one or more interior surfaces of the debris separator device1002. For example, the edges1102,1103,1104shown inFIG. 11are curved so as to fit within and abut a curved interior surface of the debris separator device1002such that fluid cannot easily pass between the interior surface of the debris separator device1002and the edges1102,1103,1104of the weir plate1100.

The weir plate1100can include one or more flow openings1106,1107,1108. Fluid can flow through the flow openings1106,1107,1108of the weir plate1100within debris separator device1002. Although the weir plate1100shown inFIG. 11has three flow openings1106,1107,1108, more or fewer flow openings can be included. The shape, location and orientation of the flow openings1106,1107,1108may differ for different weir plates so as to create a desired tortuous fluid flow path within debris separator device1002. The weir plate1100can include a slot1110for receipt of a second weir plate to form a weir as described in greater detail with reference toFIG. 12.

FIG. 12depicts an example weir1200, in accordance with some aspects. The weir1200shown inFIG. 12includes the first weir plate1100ofFIG. 11, coupled to a second weir plate1202via the slot1110of the first weir plate1100and a slot1204of the second weir plate1202. However, the weir1200additionally or alternatively may include more or fewer weir plates1100,1202or use other couplers. The weir1200can include a plurality of wings1206,1207,1208,1209. In various aspects, a major portion of a first wing1206of the plurality of wings1206,1207,1208,1209is nonparallel to a major portion of a second wing1207of the plurality of wings1206,1207,1208,1209. In some aspects, the weir1200can include a single unit having a plurality of wings1206,1207,1208,1209rather than coupled weir plates1100,1202. In some aspects, the components of the weir1200are arranged such that flow openings of a first wing1100,1208of the weir1200cause solids to deposit on a second wing1206,1207of the same weir1200, e.g., causing the second wing1206to function as a debris-capturing pocket.

The wings1206,1207,1208,1209of the weir1200can be oriented so as to create a tortuous fluid flow path and increase the separation of solids from fluid within the debris separator device1002. As an illustrative example, fluid flowing in the direction indicated by arrows1212,1213can be forced through flow openings1106,1216. The fluid can continue through the flow openings1107,1108,1217,1218. During this movement, solids may be deposited at the portion of the first weir plate1100between flow opening1107and flow opening1108. Solids may also be deposited at the portion of the second weir plate1202between flow opening1217and flow opening1218. In sum, the flow opening1106of wing1209can cause solids to deposit at wing1206without obstructing one or more of the flow openings1217,1218of the wing1206. and the flow opening1216of wing1208can cause solids to deposit at wing1207without obstructing one or more of the flow openings1107,1108of the wing1207. While the weir1200shown inFIG. 12includes two weir plates1100,1202of the same design, in some aspects, the weir1200may comprise weir plates of different designs. For example, the second weir plate1202may comprise more or less flow openings1216,1217,1218than the first weir plate1100, and the flow openings1216,1217,1218may be of any size and shape suitable to create a desired tortuous fluid flow path.

FIG. 13depicts an example weir assembly1300, according to various aspects. The weir assembly1300generally can include a weir, for example, the weir1200ofFIG. 12, a first portion of an insert1302, and a second portion of an insert1304. The weir1200can be inserted into a slot1306of the first portion of the insert1302. While the slot1306is shown inFIG. 13as ridges1307,1308, any of a variety features may be used to form the slot1306or maintain the location and orientation of the weir1200in the first portion of the insert1302. The second portion of the insert1304can also include a slot to maintain the location and orientation of the weir1200within the second portion of the insert1304.

The second portion of the insert1304can be coupled to the first portion of the insert1302by bonding at1301and1303. Non-limiting examples of bonding include adhesives, welds, solder, and other surface joining techniques or materials. Any other suitable coupler additionally or alternatively may be used, including, but not limited to other couplers discussed herein, combinations thereof, or the like. The bonding may fix the orientation of the bonded pieces relative to one another. Each of the first and second portions of the insert,1302,1304shown inFIG. 13include coupling edges1310,1311,1312,1313. These features can function as couplers to facilitate coupling of the weir assembly1300to another weir assembly or other apparatus. However, other couplers may also be used to couple the weir assembly1300with other components within the debris separator device1002. Weir assemblies may be coupled together in an arrangement that causes weirs to be oriented differently from one another (e.g., as the weirs1014A and1014B are aligned differently to one another inFIG. 10). Such an arrangement may increase an amount of debris separation provided by the debris separator device1002

Example #4 Debris Separator Device with Impellers

FIGS. 14-16illustrate yet another example of a debris separator device1428. The debris separator device1428can include impellers1450, which may generate a vortex to separate debris, such as through centrifugal force on the debris. The debris may be directed by the impellers1450into annular pockets formed by baffles1454. The debris separator device1428can be modular by including contact surfaces (or other features) that allow the impellers1450or baffles1454(or inserts1490,1492in which they are housed) to be readily added, subtracted, or substituted to change the operation debris separator device1428.

FIG. 14is a perspective cutaway view of the debris separator device1428. The debris separator device1428may include an impeller1450having a plurality of blades1452that can generate a vortex of mud in the debris separator device1428, e.g., as the debris separator device1428is lowered into the wellbore. As illustrated, the debris separator device1428may include several such impellers1450disposed at intervals along the length of the debris separator device1428. As debris laden mud enters the debris separator device1428, the mud may begin to rotate and form a vortex as it passes over the impeller blades1452. In some embodiments, the impellers1450are stationary with respect to debris separator device1428, so that the fluid rotates as a result of the force of the fluid passing over the blades1452. As the fluid vortex rotates, the cuttings, debris, and other heavier particles in the mud may be thrown to the outer circumferential section of the vortex due to the centrifugal inertia of these heavier particles. Thus, the impeller1450may function to centrifuge the mud.

The debris separator device1428may also include a baffle1454. The baffle1454can catch the heavy particles that are thrown to the outside of the mud vortex via the impeller1450. Specifically, the baffle1454may feature an annular cup shape that forms an outer circumferential pocket1456within the debris separator device1428to capture cuttings from the vortex of mud generated by the impeller1450. In some embodiments, the baffle1454may also include a reduced diameter nozzle1458that forms a wall of the annular pocket1456and directs surface-pumped fluid through the center of the debris separator device1428to draw the cuttings out of the outer circumferential pocket1456when desired. The reduced diameter nozzle1458may enable clean mud to pass through the center of the baffle1454toward the float collar and main casing string described above.

The debris separator device1428shown inFIG. 14can include several such baffles1454disposed periodically along the length of the debris separator device1428. In some embodiments, the baffles1454and impellers1450may be positioned along the length of the debris separator device1428in an alternating fashion, although other arrangements may be used in other embodiments. As illustrated, one or more of the baffles1454may be disposed adjacent a corresponding impeller1450such that, as debris separator device1428is lowered into the wellbore, the mud enters the debris separator device1428(in a direction indicated by arrow1460) and moves across the impeller1450toward the baffle1454. This may allow the impeller1450to force the mud into a vortex prior to the mud reaching the baffle1454.

FIGS. 15 and 16illustrate embodiments of an impeller insert1490and a baffle insert1492, respectively. As shown inFIG. 15, the impeller insert1490may include an outer circumferential wall1494that surrounds the plurality of impeller blades1452. As discussed above, the impeller1450may include stationary blades1452that do not rotate with respect to the casing system. The blades1452ofFIG. 15may be coupled and held stationary with respect to the outer circumferential wall1494of the impeller insert1490. The impeller insert1490may be disposed in a length of tubular member (such as the casing string112ofFIG. 1) and attached to an inner surface of the tubular member to secure the impeller1450within the tubular member.

As illustrated inFIG. 16, the baffle insert1492may also include an outer circumferential wall1496that surrounds the outer circumferential pocket1456and the reduced diameter nozzle1458of the baffle1454. The baffle insert1492may be disposed in a length of tubular member (such as the casing string112ofFIG. 1) and attached to an inner surface of the tubular member to secure the baffle1454within the tubular member at a desired position relative to the impeller insert1490. The impeller insert1490and the baffle insert1492may include outer circumferential walls1494and1496that are approximately the same inner and outer diameters, e.g., in order to create a smooth internal flow path for mud that enters the casing system as the system is lowered into the wellbore. These inserts1490and1492may feature contact surfaces that allow the inserts1490and1492to be relatively easy to stack against each other, allowing a user to install as many or as few inserts as desired by simply placing the inserts1490and1492inside a portion of casing. For example, the user may install these inserts into the shoe track behind the casing shoe of the casing system. Accordingly, the inserts1490and1492may facilitate a plurality of impellers1450and baffles1454that are attachable to one another (e.g., by stacking or other couplers) to form a string of impellers1450and baffles1454of any length and having any ratio of impellers1450to baffles1454. Any desirable number of impeller inserts1490and baffle inserts1492may be utilized to form this string of components. In other embodiments, the impeller1450and the baffle1454may be components that are attachable to one another to form the debris separator device1428without being installed as inserts. For example, the components may be connected by a mandrel or other structure along a periphery or other location of the components.

Processes for Implementing Modular Debris Separators

FIG. 17is a flow chart illustrating a process1700of implementing a modular debris separator device. The process1700may utilize any combination of components and couplers, including any of those discussed above. In some aspects, the process has particular application for the debris separator devices discussed above or other debris separator devices that are flushable (e.g., that include components arranged such that fluid flow can be directed in a second direction to flush debris from surfaces that had captured debris from fluid flow in a first direction).

At block1720, the process1700can include inserting a first component into a tubular, e.g., casing string112inFIG. 1. The first component can be part of or included in a set of modular components that can be coupled together in different combinations to form respectively different configurations of a modular debris separator assembly. As non-limiting examples, the first component can be any of the above-described plates, mandrels, end caps, screens, weirs, weir plates, insert sections, impellers, baffles, sections, or inserts.

At block1720, the process1700can include inserting a second component into the tubular. Like the first component, the second component can also be part of or included in the set of modular components that can be coupled together in different combinations to form respectively different configurations of a modular downhole debris separator assembly. In some aspects, the first component and the second component may be components from different of the previously discussed numbered Examples #1-4.

At block1730, the process1700can include coupling the first component with the second component. Coupling the first and second components can form at least a part of the downhole modular debris separator assembly, e.g., the downhole modular debris separator that can be formed by the set of components. Any suitable coupler or coupling technique can be used to perform this coupling operation. As non-limiting examples, the first component and the second component may be coupled by snap-fitting interfaces (e.g., the illustrated prongs of Example 1 or other structures that are sized to deflect when being received by a mating structure and to return toward an un-deflected state when moved to a fully received or engaged state with that mating structure), cooperating threads (e.g., the illustrated threads of Example 2), securing pins (e.g., the illustrated key of Example 1 or other pins that traverse openings of multiple components), bonding (e.g., the illustrated insert sections of Example 3), slip-fitting interfaces (e.g., the illustrated slots of the weirs of example 3 or other structures sized relative to one another so as to be moveable relative to one another by hand), or stacking interfaces (e.g., the illustrated impeller inserts and baffle inserts of Example 4). Such couplers may be utilized with any components, not solely the components in the foregoing examples. Additionally, although the figures corresponding to the foregoing examples illustrate specific combinations of debris separating techniques and coupling techniques, other combinations are possible.

The order of operations of blocks1720,1720, and1730may be varied according to different aspects. In some aspects, coupling may occur after the first component is inserted into the tubular. As an illustrative example, a first component (e.g., a baffle insert) may be installed in the tubular, and the second component (e.g., an impeller insert) may be coupled with the first while the first is located in the tubular. This may allow operators to assemble and install a debris separator device in a single operation, such as may provide time savings in some scenarios. In some aspects, coupling may occur before the second component is inserted into the tubular. As an illustrative example, a first component (e.g., an end cap) and a second component (e.g., a mandrel) may be coupled together before installing a completed assembly into a tubular. This may allow components to be reached more easily to engage couplers, such as may facilitate ease of assembly in some scenarios.

In some aspects, e.g., at block1740, the first and second components (e.g., weir assemblies) can be coupled with an additional number of components of the set (e.g., an additional number of weirs assemblies). The additional number of components may be selected so as to form a downhole modular debris separator assembly of a target length (e.g., such as one half or other fraction of a length of joint of a casing string112). For example, this may allow a debris separator to be assembled on site with a length determined by space constraints, debris levels, or other parameters of a particular well. In general, the modular construction of debris separator devices such as shown and described herein can allow the components of the debris separator device to be collectively assembled and inserted into a tubular member. Alternatively, the components can be added to components of an assembly already positioned within a tubular member. Additionally, the components of the debris separator device can be transported to a worksite in an already-assembled fashion or an unassembled fashioned for construction at the site.

In some aspects, a downhole assembly, a system, or a method is provided according to one or more of the following examples or according to some combination of the elements thereof. In some aspects, a tool or a system described in one or more of these examples can be utilized to perform a method described in one of the other examples.

Provided can be a debris separator comprising a plurality of modular components that are each modular by including at least one coupler formed so as to be connectable with a coupler of another component of the plurality of modular components, the plurality of modular components connectable together by the couplers into an assembly that is positionable downhole in a well to separate debris from wellbore fluid passed through the assembly.

Provided can be the debris separator of Example #1, wherein the assembly comprises at least one of: (i) plates with pass-through areas angularly offset from one another within the assembly; (ii) screens covering different portions of a bore of a tubular and longitudinally offset from one another; (iii) weirs; or (iv) impellers and baffles.

Provided can be the debris separator of Example #1 (or any of Examples #1-2), wherein at least one pair of the plurality of modular components are connectable together by couplers that comprise snap-fitting interfaces that include at least a first structure and a second structure, the first structure sized to deflect when being received by the second structure and to return toward an un-deflected state when fully received by the second structure.

Provided can be the debris separator of Example #1 (or any of Examples #1-3), wherein at least one pair of the plurality of modular components are connectable together by couplers that comprise a female threaded surface receiving a male threaded surface.

Provided can be the debris separator of Example #1 (or any of Examples #1-4), wherein at least one pair of the plurality of modular components are connectable together by couplers that comprise securing pins traversing openings in each component coupled by the securing pins.

Provided can be the debris separator of Example #1 (or any of Examples #1-6), wherein at least one pair of the plurality of modular components are connectable together by couplers that comprise slip-fitting interfaces including surfaces that are sized relative to one another so as to be moveable relative to one another by hand.

Provided can be the debris separator of Example #1 (or any of Examples #1-6), further comprising a tubular containing the assembly, wherein at least some of the plurality of the modular components are connectable with the tubular.

Provided can be a method (which may incorporate features of any of Examples #1-7) comprising: (i) inserting a first component into a tubular, the first component included in a set of components that fit together in different combinations to form respectively different configurations of a modular debris separator assembly that is positionable downhole in a well to separate debris from wellbore fluid passed through the assembly; (ii) inserting a second component of the set into the tubular; and (iii) coupling the first component with the second component so as to form at least a part of the modular debris separator assembly.

Provided can be the method of Example #8, wherein the coupling the first component with the second component occurs after inserting the first component into the tubular.

Provided can be the method of Example #8 (or any of Examples #8-9), wherein the coupling the first component with the second component occurs before inserting the second component into the tubular.

Provided can be the method of Example #8 (or any of Examples #8-10), wherein the different combinations differ in at least one of quantity of components, order of components, or relative orientation of components.

Provided can be the method of Example #8 (or any of Examples #8-11), further comprising coupling the first component and the second component with an additional number of components of the set, the additional number of components selected so as to form a downhole modular debris separator assembly of a target length.

Provided can be the method of Example #8 (or any of Examples #8-12), wherein coupling the first component with the second component comprises connecting the first component to the second component by one or more couplers arranged on or among the first component and the second component.

Provided can be the method of Example #8 (or any of Examples #8-13), wherein coupling the first component with the second component comprises coupling the first component with the second component by an intervening structure.

Provided can be the method of Example #8 (or any of Examples #8-14), wherein coupling the first component with the second component comprises bonding the first component and the second component to one another or to an intervening structure so as to fix a relative orientation between the first component and the second component.

Provided can be a system (which may incorporate features of any of Examples #1-15) comprising: (i) a first sub-assembly of a modular debris separator assembly that is positionable downhole in a well to separate debris from wellbore fluid passed through the assembly; and (ii) a number of additional sub-assemblies of the debris separator assembly coupled in series with the first sub-assembly, the number of additional sub-assemblies selected so as to extend the downhole modular debris separator assembly to a target length.

Provided can be the system of Example #16, wherein the target length is less than a length of a single joint of a tubular in which the debris separator assembly is positioned when the debris separator assembly is positioned downhole.

Provided can be the system of Example #16 (or any of Examples #16-17), wherein the first sub-assembly is coupled with the number of additional sub-assemblies by couplers comprising at least one of (i) snap-fitting interfaces; (ii) cooperating threads; (iii) securing pins; (iv) bonding; (v) slip-fitting interfaces; or (vi) stacking interfaces.

Provided can be the system of Example #18 (or any of Examples #16-18), wherein each of the sub-assemblies comprises at least one of: (i) plates with pass-through areas angularly offset from one another within the assembly; (ii) screens covering different portions of a bore of a tubular and longitudinally offset from one another; (iii) weirs; or (iv) impellers and baffles.

Provided can be the system of Example #16 (or any of Examples #16-19), further comprising: (i) a float collar; (ii) a float shoe; and (iii) a joint of a casing string positioned between the float collar and the float shoe and containing the modular debris separator assembly.

The foregoing description, including illustrated aspects and examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of this disclosure.