Completions-based well cleanout using magnetic cleanout tool

Abstract

A completion-based well cleanout system incorporating a magnetic cleanout tool. In an example, the magnetic cleanout tool is coupled to a completion string below a well tool to magnetically attract ferromagnetic debris ahead of the well tool as the completion string advances downhole. The magnetic cleanout tool includes an annular magnet carrier defining an array of magnet receptacles that receive a corresponding plurality of magnets. Ferromagnetic debris is thereby removed ahead of the well tool as the completion string advances downhole to keep the debris away from the well tool.

Description

BACKGROUND

[0001] In the drilling and completion of oil and gas wells, a number of situations arise in which solids are present in wellbore fluids such as drilling or completions fluids. For example, when drilling a well, wellbore cuttings are generated that enter the drilling fluid (mud) being circulated. Although cuttings may be removed at the surface of the well site before the mud is recirculated downhole, some may remain in the well. Some solids may end up in the completion fluid from a layer of mud on the interior of the casing string or from surface tanks. Additional debris may be generated in working in the well, such as cement particles generated during cementing, shaped charge fragments generated during perforating, pieces of downhole equipment which have been drilled and / or milled, junk lost in the hole, and so forth.

[0002] In running a well tool downhole, tool failures may be at least partially attributable to debris in the wellbore. This can be manifested, for example, by well tools getting stuck while running in hole, circulation ports becoming plugged, J-Slots being rendered inoperable due to debris, and sealing components unable to work as designed. A cleanout run is recommended to remove solids from a completion fluid, prior to deploying a well tool downhole. However, these cleanout runs are sometimes skipped, which can increase the likelihood of tool failure.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the method.

[0004] FIG. 1 is an elevation view of a well site schematically illustrating a completion string in which aspects of the disclosure may be implemented.

[0005] FIG. 2 is an elevation view of the completion string incorporating a completions-based well cleanout system according to an example configuration.

[0006] FIG. 3 is an enlarged view of the well cleanout system as used to protect the well packer and any other well tools above it that may be affected by debris.

[0007] FIG. 4 is a side view of an annular magnet carrier for the magnetic cleanout tool according to an example configuration.

[0008] FIG. 5 is a side view of the annular magnet carrier with a corresponding plurality of magnets received within the array of magnet receptacles.

[0009] FIG. 6 is a perspective view of a magnetic cleanout tool according to an example configuration using couplings to secure the magnetic cleanout tool in line with the completion string.

[0010] FIG. 7 is a perspective view of an example configuration of the coupling of FIG. 6.

[0011] FIG. 8 is a side view of a magnetic cleanout tool according to a “fixed-carrier” configuration.

[0012] FIG. 9 is a side view of a magnetic cleanout tool according to a “floating-carrier” configuration.

[0013] FIG. 10 is a sectional side view of the magnetic cleanout tool illustrating an example configuration of the annular magnet carrier.

[0014] FIG. 11 is a sectional side view of one of the end rings of FIGS. 8 and 9.DETAILED DESCRIPTION

[0015] This disclosure is directed to systems and methods of cleaning debris using a disclosed magnetic cleanout tool when running a completion string into a well. Unlike other tubing strings, which are normally tripped into a well to perform an operation and then tripped back out, a completion string is generally installable in a well such that it remains in the well for the duration of the well's useful service life. A completion string may be permanently installed, in the sense that it can remain downhole over the useful service life of the well and beyond. If a well cleanout run is skipped or overlooked prior to completion string installation, there is very limited recourse if debris left downhole were to cause a tool failure in the completion string. The present disclosure therefore provides a cleanout tool in the completion string itself rather than on a separate work string, for cleaning the wellbore ahead of a well tool carried on the completion string. In case a prior cleaning run is insufficient or even omitted prior to installing the completion string, the disclosed magnetic cleaning tools and related systems and methods can at least provide a backup for cleaning the well as the completion string is lowered into the well for installation.

[0016] Examples are disclosed wherein a completion string includes one or more well tool along with a magnetic cleanout tool coupled to the completion string. The well tool can be any tool whose operation or performance could be diminished due to the presence of debris. Non-limiting examples of such well tools include sealing elements, whose sealing performance can be reduced due to debris at a sealing interface; valves and other devices that can be clogged by debris, and instrumentation such as pressure and temperature gauges. The magnetic well tool may comprise a powerful magnet for attracting and collecting ferromagnetic debris (e.g., metallic cuttings) to remove the ferromagnetic debris from the well fluid. Various magnet configurations and ways to couple the magnet to the completion string are presented below in further specific example embodiments. By removing ferromagnetic debris magnetically, and optionally in combination with performing other non-magnetic cleaning operations, like wiping, scraping, and / or filtering ahead of the well tool, debris can be removed that might otherwise lead to a failure of the well tool.

[0017] FIG. 1 is an elevation view of a well site 10 schematically illustrating a completion string 40 in which aspects of the disclosure may be implemented. The well site 10, as depicted in FIG. 1, is simplified for discussion purposes, and is not to scale. The completion string 40 is also schematically shown, and can be configured as desired, such as to incorporate a well cleanout system with a magnetic cleanout tool as described herein. A wellbore 16 has previously been drilled below the earth's surface 14. The wellbore 16 may follow any given wellbore trajectory, using available directional drilling techniques if necessary, to reach a desired hydrocarbon-bearing portion of the formation 15. By way of example, the wellbore 16 in FIG. 1 includes a vertical wellbore portion 16A and a deviated wellbore portion 16B extending below it. A portion of the wellbore 16 may be reinforced with a tubular metal casing 24 cemented in place. Other, uncased portions of the wellbore 16 may be referred to as open-hole.

[0018] A large support structure, such as a derrick 20, is erected at the well site 10 over the wellbore 16, on a support foundation or platform, such as a rig floor 22. In a subsea context, the earth's surface 14 may alternatively represent the floor of a seabed, and the rig floor 22 may be on the offshore platform or floating rig over the water above the seabed. The derrick 20 may be used to support equipment in constructing the well. The derrick 20 may be used, for example, to support the completion string 40 as it is lowered into and / or retrieved from the wellbore 16. Such a completion string 40 may incorporate well tools such as packers, bridge plugs, subsurface safety valves, and service tools whose operation may rely on sufficiently clean well environment with minimal debris. The completion string 40 may also convey fluids from or to the earth's surface 14, and / or support the communication of signals and power during wellbore operations.

[0019] The completion string 40 may include a lower completion string 40B previously installed downhole and an upper completion string 40A that may be lowered into the wellbore 16 for connecting with the lower completion string 40B. Once installed, the lower completion string 40B is generally left in place throughout the useful service life of the well. Once the upper completion string 40A is landed and connected to the lower completion string 40B, the upper completion string 40A may also remain downhole for the useful service life of the well. Any number of well tools may be included on the completion string. For example, packers 28 or other wellbore sealing elements may be used to fluidically isolate different portions of an annulus between the completion string 40 and the wellbore 16. One or more other well tool 30 may also be incorporated elsewhere within the upper completion string 40A and lower completion string 40B that collectively form the completion string 40 in this example. As further discussed below, a well cleanout tool may be incorporated in the upper and / or lower completion strings 40A, 40B below any given well tool.

[0020] FIG. 2 is an elevation view (not to scale) of the completion string 40 incorporating a completions-based well cleanout system 100 according to an example configuration. The completion string 40 extends from the earth's surface 14 at the well site down to or beyond the hydrocarbon-bearing portion of the formation 15. A casing hanger (not shown) is installed in the wellbore 16 for suspending a surface casing 44 and a production tubing 46 below it. The casing hanger may be close to the surface 14 or at a depth below the surface 12. Various additional well tools are provided in the completion string 40. For example, a tubing-retrievable safety valve (TRSV) 48 is provided in-line with the production tubing 46 for controlling flow of production fluids, such as to shut off flow of production fluids in the event of an emergency. Below the TRSV 48 is instrumentation 50, which may comprise a downhole pressure and / or temperature gauge. Further down the completion string 40 is a polish bore assembly (PBA) 52 that may allow string movement. Below the PBA 52 is a production packer 54, which is actuatable into sealing engagement with the wellbore 16. A perforated region 56 of the well allows for the flow of production fluid from the formation 15 into the completion string 40 and up the completion string 40 to the surface 14.

[0021] One or more of the tools in the completion string 40 can be potentially affected by the presence of debris in the well. The TRSV 48, or any valve more generally, is an example of a well tool affected by too much debris, such as by interfering with mechanical movement of an actuator, compromising a sealing surface, or clogging flow in smaller valves. The instrumentation 50 is another example of a well tool whose operation or performance could be diminished due to the presence of debris, such as by debris clogging a flow part used in the instrumentation 50. The PBA 52 is yet another example of a well tool in the completion string 40 whose operation or performance could be diminished due to the presence of debris, such as by contaminating a polished bore of the PBA 52. Finally, the production packer 54 is still another example of a tool whose performance or operation could be diminished by debris, such as be interfering with a seal between the production packer 54 and the wellbore 16. The well cleanout system generally outlined at 100 is positioned below all of these examples of well tools. The well cleanout system 100 is used to remove debris while tripping in to at least reduce the amount of debris that might otherwise reach the various well tools above it.

[0022] FIG. 3 is an enlarged view of the well cleanout system 100 (not to scale) as used to protect the production packer 54 and any other well tools above it that may be affected by debris. The well cleanout system 100 may have any of a variety of configurations of a magnetic cleanout tool 60 coupled to the completion string 40 below the production packer 54. The magnetic well tool 60 may comprise a powerful magnet for attracting and collecting ferromagnetic debris 102 (e.g., metallic cuttings) to remove the ferromagnetic debris 102 from the well fluid. By positioning the magnetic cleanout tool 60 below the production packer 54, at least some ferromagnetic debris 102 may be removed from the wellbore ahead of the production packer 54 as the completion string 40 is tripped in to the well.

[0023] Additional, e.g., stray debris is schematically shown at 104. The stray debris 104 may comprise, for example, non-ferromagnetic debris or a smaller amount of ferromagnetic debris that is dislodged from or otherwise able to move past the magnetic cleanout tool 60. The well cleanout system 100 optionally includes additional cleanout features that can help remove the stray debris 104 from the well fluid before it reaches the production packer 54 or other well tool to be protected. In this example, the additional cleanout features include an optional slip-on annulus filter tool 70 coupled to the completion string40 below the production packer 54 but above the magnetic cleanout tool 60 to filter out the stray debris 104 before it reaches the production packer 54.

[0024] Another optional feature of the well cleanout system 100 is a borehole engagement member 80 coupled to the completion string 40 below the production packer 54 or other well tool to be protected. The borehole engagement member 80 is positioned for slidingly contacting an inner surface of the wellbore 16 to dislodge debris as the completion string 40 advances downhole. A borehole engagement member, generally, can be any suitable structure, such as a brush or scraper, for slidingly contacting the wellbore 16 to dislodge debris from the wellbore 16. In this example, the borehole engagement member 80 comprises a pair of axially-spaced brushes 82. Thus, as the completion string 40 is advanced downhole, the borehole engagement member 80 dislodges any debris from the wellbore 16 ahead of the production packer 54, so that the inner surface of the wellbore 16 is in better condition for sealing engagement by the production packer 54 once actuated. The wellbore engagement member 80 is also optionally coupled to the completion string 40 below the magnetic cleanout tool 60, so that any ferromagnetic debris 102 dislodged by the wellbore engagement member 80 might accumulate on the magnetic cleanout tool 60. Then, stray debris 104 that makes it past the magnetic cleanout tool 60 can be filtered out by the annulus filter tool 70.

[0025] FIG. 4 is a side view of an annular magnet carrier 62 for the magnetic cleanout tool according to an example configuration. When installed in the completion string, the annular magnet carrier 62 may be coaxial with the completion string of FIGS. 2 and 3, thus sharing an axis 41. The annular magnet carrier 62 may be installed about a base pipe 58, indicated here with hidden lines. The base pipe 58 defines an internal flow path for well fluids flowing through the magnetic cleanout tool and up the annulus between the completion string and wellbore / casing. The annular magnet carrier 62 may comprise two or more arcuate carrier portions arranged to collectively encircle the base pipe 58, such as split halves (i.e., two arcuate carrier portions), releasably secured with one another about the base pipe 58. Alternatively, the carrier 62 may be a unitary tubular body that slides over an end of the base pipe 58 during assembly. Additional optional mounting details will be provided in subsequent figures.

[0026] The magnet carrier 62 defines an array of magnet receptacles 64 that, with corresponding magnets once received therein, are axially and circumferentially spaced relative to the axis 41. The spacing and dimensions of the magnet receptacles 64 in this example are generally uniform, with an axial spacing “SA,” a circumferential spacing “Sc,” a length “LA” as measured axially, and a width “Lc” as measured circumferentially. The spacings and dimensions are not limited to what is shown in FIG. 4. These dimensions and spacings may vary depending on the embodiment, such as based on wellbore parameters like the size of the wellbore, the overall dimensions of the magnetic cleanout tool, or manufacturing preferences.

[0027] FIG. 5 is a side view of the annular magnet carrier 62 showing a corresponding plurality of magnets 65 received within the array of magnet receptacles 64. Each magnet receptacle 64 is capable of receiving at least one magnet 65, although it may be possible to stack more than one magnet 65 in each magnet receptacle depending on dimensions and so forth. A technical advantage of having multiple, spaced-apart magnet receptacles 64 is for ease of assembly and replacement of the corresponding magnets 65. Having multiple, smaller magnets 65 that are individually positioned may be more economical to manufacture and / or replace than to manufacture and / or replace a larger or even unitary magnet.

[0028] The magnets may be permanent magnets, such as neodymium. A neodymium magnet is an example of a rare-earth magnet. It is a permanent magnet made from an alloy of neodymium, such as a combination of neodymium, iron, and boron. The magnet material may be any of a variety of permanent magnet materials. The particular magnet material may be selected based, for example, on well conditions, such as temperature. Typically, a neodymium magnet material is sufficiently strong and economical. The shape of the receptacles 64 and magnets 65 is typically rectangular. The magnets 65 may be available in a variety of sizes, such as from 0.25 inches (~6.3 mm) thick up to 1 inch (~25.4 mm) thick or more. The magnets may also be available in different grades known in industry, such as N45, N52 and so forth. Different form factors, such as long bars, may also be suitable. Since the magnets 65 can have a high magnetic strength, the annular magnet carrier 62 may comprise a non-ferromagnetic material, such as aluminum or a polymer, to facilitate positioning the magnets 65 in or removing the magnets 65 from the magnet receptacles 64.

[0029] The example of FIG. 5 further includes a retention sleeve 66 (shown in cutaway view) removably disposed about the annular magnet carrier 62 to retain the corresponding magnets 65 in the magnet receptacles 64. The retention sleeve 66 may also comprise a non-ferromagnetic material, such as aluminum or a polymer. Using a non-ferromagnetic material rather than a ferromagnetic material for the retention sleeve 66 can ease assembly, such as by sliding the retention sleeve 66 past the magnets 65.

[0030] FIG. 6 is a perspective view of a magnetic cleanout tool 160 according to an example configuration using couplings 110 to secure the magnetic cleanout tool 160 in line with the completion string 40. The annular magnet carrier 62 may be as described in preceding figures. The couplings 110 may include threaded connections 112 (male or female) at either end, for threadedly coupling to components of the completion string 40. The couplings 110 may also axially constrain the annular magnet carrier 62 and retention sleeve 66 relative to the completion string. The couplings 110 also comprise end collars 114 at opposing ends. The end collars 114 extend radially outwardly of the annular magnet carrier 62 with respect to the axis 41 that passes longitudinally through the magnetic cleanout tool 160. The end collars 114 may radially space the magnetic cleanout tool from the wellbore 16, to protect the annular magnet carrier 62 and magnets 65, and to allow debris-laded fluid to flow more uniformly about the annular magnet carrier 62. The end collars 114 may thus serve as centralizers in helping to approximately center the magnetic cleanout tool 160 within the wellbore 16. The end collars 114 may be used in lieu of, or in addition to, other types of centralizers, like bow-spring centralizers coupled to the magnetic cleanout tool 160 or to the completion string 40 above and below the magnetic cleanout tool 160.

[0031] FIG. 7 is a perspective view of an example configuration of the coupling 110 of FIG. 6. The coupling 110 is configured as a centralizer with a threaded male pin end 112A and female threaded box end 112B. In an example, the coupling 110 could be a three-way adapter with configured as an API-EU box-box coupling with pin end on the outer diameter (OD).

[0032] FIG. 8 is a side view of a magnetic cleanout tool 260 according to a “fixed-carrier” configuration. The annular magnet carrier 62 may be as described in preceding figures. End rings 120 are secured to a base 58 at opposing longitudinal ends 61, 63 of the annular magnet carrier 62. In this example, the end rings 120 are abutting the longitudinal ends 61, 63 so as to prevent any appreciable axial movement of the annular magnet carrier 62 with respect to the base pipe 58.

[0033] FIG. 9 is a side view of a magnetic cleanout tool 360 according to a “floating-carrier” configuration. The annular magnet carrier 62 may again be as described in preceding figures. The end rings 120 limit axial movement of the annular magnet carrier 62 with respect to the base pipe 58. However, the end rings 120 are spaced further apart than a length “L” of the annular magnet carrier 62 so as to allow some floating axial movement of the annular magnet carrier 62 between the end rings 120. In other configurations, the end rings 120 may be a joint of tubing wherein axial movement may be limited to the larger outer diameter of the couplings / threaded connection to the next joint of pipe.

[0034] FIG. 10 is a sectional side view of the magnetic cleanout tool 60 illustrating an example configuration of the annular magnet carrier 62. In this example, the annular magnet carrier 62 comprises two arcuate carrier portions (i.e., split halves) 62A, 62B, arranged to collectively encircle the base pipe 58. The arcuate carrier portions 62A, 62B are releasably secured with one another about the base pipe 58 using fasteners, such as threaded members 130. Fasteners could be configured in many different ways. In this example, each threaded member 130 comprises a bolt that passes through a bolt hole 132 defined in one arcuate carrier portion 62A or 62B and into a threaded portion 134 of the other arcuate carrier portion 62A or 62B. This type of annular magnet carrier configuration comprising two (or more) arcuate portions allows the annular magnet carrier 62 to be assembled to or disassembled from the base pipe 58. The magnets may be installed in magnet receptacles on the annular magnet carrier portions 62A, 62B before or after securing the annular magnet carrier portions 62A, 62B to the base pipe 58.

[0035] FIG. 11 is a sectional side view of one of the end rings 120 of FIGS. 8 and 9. The end ring 120 defines an inner diameter (ID) 122 sized to receive a base pipe 58 or other tubular member to which the end ring 120 is to be secured. The end ring 120 also defines a plurality of circumferentially-spaced, radially-oriented holes 124 for receiving corresponding fasteners 126. The holes 124 may be internally threaded for threaded engagement by external threads on the fasteners 126. Thus, the fasteners 126 may be uniformly tightened about the end ring 120 to drive the fasteners 126 into biting engagement with an OD of the base pipe 58.

[0036] The foregoing examples (e.g., in FIGS. 6, 8, and 9) each show just one annular magnet carrier 62 per magnetic cleanout tool. However, it should be recognized that two or more annular magnet carriers may be arranged end to end, such as between end rings or couplings, so as to cover any desired axial length for a magnetic cleanout tool. Additionally, or in the alternative, multiple magnetic cleanout tools may be arranged, such as axially spaced along a completion string, or at different locations in a completion string, with each magnetic cleanout tool positioned below a well tool it is intended to protect from debris.

[0037] The foregoing completions-based cleanout system incorporating a magnetic cleanout tool, and related methods, are provided by way of example and include but are not limited to what is recited in the following statements.

[0038] Statement 1: A completion-based well cleanout system, comprising: a completion string installable downhole in a well; a well tool coupled to the completion string; and a magnetic cleanout tool coupled to the completion string below the well tool to magnetically attract ferromagnetic debris ahead of the well tool as the completion string advances downhole, the magnetic cleanout tool comprising an annular magnet carrier defining an array of magnet receptacles that receive a corresponding plurality of magnets.

[0039] Statement 2: The completion-based well cleanout system of any of the preceding statements, further comprising: a base pipe defining a portion of an internal flow path of the completion string, wherein the annular magnet carrier is disposed about the base pipe.

[0040] Statement 3: The completion-based well cleanout system of any of the preceding statements, wherein the annular magnet carrier comprises two or more arcuate carrier portions releasably securable to collectively encircle the base pipe.

[0041] Statement 4: The completion-based well cleanout system of any of the preceding statements, wherein the annular magnet carrier comprises a unitary tubular body that encircles the base pipe.

[0042] Statement 5: The completion-based well cleanout system of any of the preceding statements, wherein the array of magnet receptacles and corresponding magnets are axially and circumferentially spaced relative to the axis of the completion string.

[0043] Statement 6: The completion-based well cleanout system of any of the preceding statements, wherein the magnetic cleanout tool further comprises a retention sleeve disposed about the annular magnet carrier to retain the magnets in the magnet receptacles.

[0044] Statement 7: The completion-based well cleanout system of any of the preceding statements, further comprising end collars at opposing longitudinal ends of the annular magnet carrier.

[0045] Statement 8: The completion-based well cleanout system of any of the preceding statements, wherein the end collars comprise centralizers radially extending from the carrier to radially space the magnetic cleanout tool from a wellbore about the magnetic cleanout tool.

[0046] Statement 9: The completion-based well cleanout system of any of the preceding statements, wherein the annular magnet carrier is formed of a non-magnetic material and the magnets comprise neodymium magnets.

[0047] Statement 10: The completion-based well cleanout system of any of the preceding statements, further comprising: a filter and / or a borehole engagement member coupled to the completion string below the well tool, the filter positioned for filtering at least some debris not collected by the magnetic cleanout tool, the borehole engagement member positioned for slidingly contacting an inner surface of a wellbore to dislodge debris as the completion string advances downhole.

[0048] Statement 11: The completion-based well cleanout system of any of the preceding statements, wherein the well tool comprises a packer actuatable into sealing engagement with the wellbore, a downhole gauge, and / or a safety valve.

[0049] Statement 12: A magnetic cleanout tool for a well completion string, comprising: a base pipe securable to a completion string and defining an internal flow path for flow through the completion string; an annular magnet carrier disposed about the base pipe, the annular magnet carrier defining an array of magnet receptacles; and a corresponding plurality of magnets received by the magnet receptacles and arranged to magnetically attract ferromagnetic debris ahead of a well tool.

[0050] Statement 13: The magnetic cleanout tool of any of the preceding statements, wherein the annular magnet carrier comprises two or more arcuate carrier portions arranged to collectively encircle the base pipe and releasably secured with one another about the base pipe.

[0051] Statement 14: The magnetic cleanout tool of any of the preceding statements, wherein the annular magnet carrier comprises a unitary sleeve that encircles the base pipe.

[0052] Statement 15: The magnetic cleanout tool of any of the preceding statements, wherein the magnetic cleanout tool further comprises a retention sleeve disposed about the annular magnet carrier to retain the magnets in the magnet receptacles.

[0053] Statement 16: The magnetic cleanout tool of any of the preceding statements, further comprising end collars at opposing longitudinal ends of the annular magnet carrier.

[0054] Statement 17: The magnetic cleanout tool of any of the preceding statements, wherein the end collars comprise centralizers radially extending from the carrier to radially space the magnetic cleanout tool from a wellbore about the magnetic cleanout tool.

[0055] Statement 18: A method, comprising: deploying a completion string into a wellbore carrying a well tool and a magnetic cleanout tool below the well tool; magnetically attracting ferromagnetic debris ahead of the well tool as the completion string advances downhole to keep the attracted ferromagnetic debris away from the well tool; securing the completion string downhole; and performing a tool function downhole using the well tool.

[0056] Statement 19: The method of any of the preceding statements, wherein the well tool comprises a packer and performing a tool function comprises expanding the packer to sealingly engage the wellbore.

[0057] Statement 20: The method of any of the preceding statements, further comprising: one or both of wiping an interior surface of the wellbore ahead of the well tool as the completion string advances downhole and / or filtering wellbore fluid ahead of the well tool using a filtering sleeve as the completion string advances downhole.

[0058] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

[0059] Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

Claims

1. A completion-based well cleanout system, comprising:a completion string installable downhole in a well;a well tool coupled to the completion string; anda magnetic cleanout tool coupled to the completion string below the well tool to magnetically attract ferromagnetic debris ahead of the well tool as the completion string advances downhole, the magnetic cleanout tool comprising an annular magnet carrier defining an array of magnet receptacles that receive a corresponding plurality of magnets.

2. The completion-based well cleanout system of claim 1, further comprising:a base pipe defining a portion of an internal flow path of the completion string, wherein the annular magnet carrier is disposed about the base pipe.

3. The completion-based well cleanout system of claim 2, wherein the annular magnet carrier comprises two or more arcuate carrier portions releasably securable to collectively encircle the base pipe.

4. The completion-based well cleanout system of claim 2, wherein the annular magnet carrier comprises a unitary tubular body that encircles the base pipe.

5. The completion-based well cleanout system of claim 1, wherein the array of magnet receptacles and corresponding magnets are axially and circumferentially spaced relative to the axis of the completion string.

6. The completion-based well cleanout system of claim 1, wherein the magnetic cleanout tool further comprises a retention sleeve disposed about the annular magnet carrier to retain the magnets in the magnet receptacles.

7. The completion-based well cleanout system of claim 1, further comprising end collars at opposing longitudinal ends of the annular magnet carrier.

8. The completion-based well cleanout system of claim 7, wherein the end collars comprise centralizers radially extending from the carrier to radially space the magnetic cleanout tool from a wellbore about the magnetic cleanout tool.

9. The completion-based well cleanout system of claim 1, wherein the annular magnet carrier is formed of a non-magnetic material and the magnets comprise neodymium magnets.

10. The completion-based well cleanout system of claim 1, further comprising:a filter and / or a borehole engagement member coupled to the completion string below the well tool, the filter positioned for filtering at least some debris not collected by the magnetic cleanout tool, the borehole engagement member positioned for slidingly contacting an inner surface of a wellbore to dislodge debris as the completion string advances downhole.

11. The completion-based well cleanout system of claim 10, wherein the well tool comprises a packer actuatable into sealing engagement with the wellbore, a downhole gauge, and / or a safety valve.

12. A magnetic cleanout tool for a well completion string, comprising:a base pipe securable to a completion string and defining an internal flow path for flow through the completion string;an annular magnet carrier disposed about the base pipe, the annular magnet carrier defining an array of magnet receptacles; anda corresponding plurality of magnets received by the magnet receptacles and arranged to magnetically attract ferromagnetic debris ahead of a well tool.

13. The magnetic cleanout tool of claim 12, wherein the annular magnet carrier comprises two or more arcuate carrier portions arranged to collectively encircle the base pipe and releasably secured with one another about the base pipe.

14. The magnetic cleanout tool of claim 12, wherein the annular magnet carrier comprises a unitary sleeve that encircles the base pipe.

15. The magnetic cleanout tool of claim 12, wherein the magnetic cleanout tool further comprises a retention sleeve disposed about the annular magnet carrier to retain the magnets in the magnet receptacles.

16. The magnetic cleanout tool of claim 12, further comprising end collars at opposing longitudinal ends of the annular magnet carrier.

17. The magnetic cleanout tool of claim 16, wherein the end collars comprise centralizers radially extending from the carrier to radially space the magnetic cleanout tool from a wellbore about the magnetic cleanout tool.

18. A method, comprising:deploying a completion string into a wellbore carrying a well tool and a magnetic cleanout tool below the well tool;magnetically attracting ferromagnetic debris ahead of the well tool as the completion string advances downhole to keep the attracted ferromagnetic debris away from the well tool;securing the completion string downhole; andperforming a tool function downhole using the well tool.

19. The method of claim 18, wherein the well tool comprises a packer and performing a tool function comprises expanding the packer to sealingly engage the wellbore.

20. The method of claim 18, further comprising:one or both of wiping an interior surface of the wellbore ahead of the well tool as the completion string advances downhole and / or filtering wellbore fluid ahead of the well tool using a filtering sleeve as the completion string advances downhole.

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