Autonomous Wellbore Cleaner With Sensor-Triggered Scale Removal
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Solution Overview
Problem
Conventional downhole cleaning tools require multiple trips and activations for effective wellbore cleaning, are limited to a single cleaning cycle, and are not autonomous, leading to inefficiencies and increased operational time.
Innovation Solution
An autonomous wellbore cleaning device equipped with an autonomous robot or tractor, combined with cleaning tools such as brushes, water jets, or sonic cleaners, that can detect scale buildup and adjust operations accordingly, allowing for untethered operation and periodic cleaning within the wellbore.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional downhole cleaning tools are used, then cleaning operations can be performed, but multiple trips and activations are required leading to increased operational time and reduced productivity
Solution Approach 1:
The cleaning tool is equipped with an autonomous robot or tractor that can independently navigate the wellbore, detect scale buildup using sensors, and initiate cleaning operations without requiring multiple trips or external activation. The tool serves itself by autonomously determining when and where cleaning is needed, eliminating the need for repeated deployments and reducing operational time while maintaining high cleaning efficiency
Solution Approach 2:
The cleaning tool incorporates sensors that detect scale buildup and provide feedback to the control system. This feedback mechanism allows the autonomous robot to identify areas requiring cleaning, monitor cleaning effectiveness, and adjust operations in real-time, enabling a single deployment to complete multiple cleaning cycles based on actual wellbore conditions rather than requiring predetermined multiple trips
2Device complexity
If conventional cleaning tools with single activation cycle are used, then device complexity is reduced, but the need for multiple deployments increases leading to higher operational costs
Solution Approach 1:
The tool incorporates an autonomous robot or tractor with onboard sensors and control systems that enable it to independently perform multiple cleaning cycles during a single deployment. The robot autonomously navigates the wellbore, detects scale buildup, and activates cleaning tools as needed, allowing one deployment to accomplish what previously required multiple deployments, thereby increasing productivity without proportionally increasing device complexity
Solution Approach 2:
The cleaning tool is designed as a multi-functional system that combines navigation (autonomous robot/tractor), detection (sensors for scale buildup), and cleaning capabilities in a single deployable unit. This universal design allows the same tool to perform multiple cleaning operations at different locations along the wellbore during one deployment, eliminating the need for multiple specialized tools or repeated deployments
3Reliability
If frequent cleaning operations are performed, then scale buildup is better controlled, but energy consumption increases
Solution Approach 1:
The system uses sensors to detect scale buildup and provides feedback to the control system, which activates cleaning operations only when scale detection exceeds predetermined thresholds. This feedback-controlled approach ensures frequent cleaning when needed to maintain reliability and scale removal effectiveness, while avoiding unnecessary cleaning operations that would waste energy, thus optimizing the balance between scale control and energy consumption
Solution Approach 2:
The autonomous robot performs cleaning operations periodically based on sensor feedback rather than continuously. The system monitors scale buildup over time and initiates cleaning cycles only when detection indicates it is necessary, creating a periodic action pattern that maintains effective scale removal while conserving energy by avoiding continuous or unnecessary cleaning operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates frequent and targeted cleaning, easier removal of thin scale layers, and conserves energy by optimizing cleaning intervals based on sensor feedback, reducing the need for multiple tool deployments and enhancing cleaning efficiency.
Implementation Method 1
at least one sensor to detect an initiate-cleaning attribute downhole in the wellbore
Implementation Method 2
The cleaning tool can be deployed to be in contact with an interior of a casing of the wellbore
Implementation Method 3
combined with cleaning tools such as brushes, water jets, or sonic cleaners
Implementation Method 4
combined with cleaning tools such as brushes, water jets, or sonic cleaners
Data Source
AI summary
Disclosed herein are an apparatus, system, and method directed for an autonomous wellbore cleaner. In one embodiment, an apparatus for cleaning a wellbore, the apparatus comprising: an autonomous robot, wherein the robot is self-propelled; a power source for the robot; a motor for propelling the robot axially within the wellbore; at least one cleaning tool positioned on the robot; at least one sensor to detect an initiate-cleaning attribute downhole in the wellbore; and a processor to direct the robot to initiate a cleaning operation in response to the initiate-cleaning attribute exceeding a threshold.