Blanking Plug Sand Flushing via Hydraulic Agitation
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Solution Overview
Problem
Sand and scale accumulation on top of blanking plugs and around ESP shafts in hydrocarbon wells leads to frequent ESP shutdowns, increased non-productive time, and premature ESP failures, necessitating costly removal operations and interventions.
Innovation Solution
A fluid tank is positioned above the blanking plug to agitate and displace accumulated sand and scale using dumped fluid, and a flushing tube is used to periodically flush away particulates, facilitating easier retrieval of the blanking plug and reducing ESP failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blanking plug is installed to prevent fluid circulation around the ESP, then ESP shutdown due to fluid circulation is prevented, but sand and scale accumulation on top of the plug body occurs
Solution Approach 1:
The patent employs hydraulic flushing using produced fluids to remove sand and scale accumulation from the top of the blanking plug. A flushing system is installed that directs high-velocity fluid jets against the accumulated solids, utilizing hydraulic pressure and flow to dislodge and transport the particulate matter away from the plug body, thereby resolving the accumulation problem while maintaining the blanking plug's primary function
2Reliability
If sand and scale accumulate on top of the blanking plug, then retrieval operations become difficult and time-consuming, but the blanking plug effectively prevents fluid circulation
Solution Approach 1:
The patent implements periodic flushing operations during production to prevent sand and scale accumulation from reaching problematic levels. By performing preliminary cleaning actions while the well is still producing, the system maintains the blanking plug surface relatively clean, so when retrieval is eventually needed, minimal or no sand removal operations are required, significantly reducing retrieval time
3Reliability
If sand and scale accumulate around the ESP shaft, then motor temperature increases and electrical shorts occur, but the blanking plug prevents fluid circulation
Solution Approach 1:
The flushing system targets not only the top of the blanking plug but also the annular space around the ESP shaft. High-velocity fluid jets are directed to remove sand and scale buildup in these critical areas, preventing insulation breakdown and electrical shorts caused by accumulated solids, while maintaining proper motor cooling flow paths
4Speed
If conventional retrieval methods are used without sand removal, then retrieval speed is fast, but sand and scale prevent successful plug removal
Solution Approach 1:
The system utilizes the well's own produced fluids as the flushing medium, eliminating the need for external water sources or complex flushing equipment. The produced fluids are redirected through the flushing system to clean the blanking plug and surrounding areas, providing a self-contained solution that maintains retrieval feasibility without requiring additional resources or significantly extending operation time
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
The solution effectively prevents sand and scale accumulation, reduces the need for costly removal operations, prolongs ESP run life, and minimizes pressure drops during oil well startup, enhancing well intervention efficiency and ESP integrity.
Implementation Method 1
fluid may be dumped from the fluid tank so as to agitate and displace sand, scale, and other particulate matter from the top of the blanking plug
Implementation Method 2
the lower end of the fluid tank may be equipped with one or more generally downwardly directed nozzles or jetting orifices for accelerating the dumped fluid against the accumulated sand, scale, or particulate matter
Implementation Method 3
water, diesel oil, or other fluid may be pumped from the surface through the flushing tube. Upon exiting the flushing tube, such pumped fluid will agitate and displace sand, scale, and other particulate matter that may have accumulated on top of the blanking plug
Data Source
AI summary
A system for producing fluids from a wellbore extending from a well surface to a fluid-producing formation has a Y-tool installed in fluid communication with the tubing string placed in the wellbore. A pump, which may be an electric submersible pump (ESP), is installed in the Y-tool for lifting fluids from the formation to the surface. A blanking plug is positioned in the tubing string between the upper and lower connections of the Y-tool. A flushing port extends through a wall of the tubing string, positioned above and near the upper end of the blanking plug when in its operating position, and a flushing tube is located in the annular space between the tubing string and the wellbore casing. The flushing tube is in fluid communication with the flushing port and extends from the flushing port to the well surface. Flushing fluid is pumped downhole through the flushing tube to agitate and disperse any accumulated sand, scale and other particulate matter on top of the blanking plug.