Downhole Clean Out Tool Using Reverse Circulation
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Solution Overview
Problem
Current wellbore cleaning processes are inefficient and time-consuming, requiring multiple clean-out runs and surface fluid cleaning to meet turbidity requirements, especially for complex well completions, which can lead to stuck completion operations and increased maintenance.
Innovation Solution
A downhole clean out tool with a sub-assembly that includes a housing with a flow path, screens, and magnetic members to catch and remove debris using reverse circulation of wellbore fluid, reducing the need for vacuum equipment and simplifying the design for effective debris removal and fluid filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple clean-out runs and surface fluid cleaning are performed to meet turbidity requirements, then the wellbore cleaning effectiveness is improved, but the cleaning time and operational complexity increase significantly
Solution Approach 1:
The patent inverts the traditional cleaning approach by using reverse circulation to flow debris upward toward the surface rather than allowing debris to settle downward. The cleanout tool includes a housing with a lower end and upper end, where fluid enters at the lower end and flows upward through the annulus, carrying debris with it. This inversion eliminates the need for multiple clean-out runs and surface fluid cleaning operations, significantly reducing cleaning time while maintaining effectiveness.
Solution Approach 2:
The patent employs hydraulic principles by utilizing wellbore fluid circulation to transport debris. The cleanout tool uses the hydraulic flow of fluid entering at the lower end and exiting at the upper end to carry debris particles upward through the annulus. This hydraulic approach replaces traditional mechanical or repeated cleaning operations, reducing the number of runs needed while achieving thorough cleaning.
2Reliability
If multiple clean-out runs are performed for complex well completions, then the turbidity requirement is met, but the operational complexity and risk of stuck completion increase
Solution Approach 1:
By inverting the flow direction to move debris upward, the patent simplifies the operational procedure. The single-run reverse circulation process eliminates the need for multiple clean-out runs and surface fluid cleaning operations, reducing operational complexity while ensuring turbidity requirements are met. The tool design with lower and upper ends facilitates this inverted flow pattern.
Solution Approach 2:
The cleanout tool performs self-service by using the wellbore fluid circulation system itself to carry out the cleaning function. The tool harnesses the existing hydraulic flow to transport debris upward through the annulus, eliminating the need for separate surface fluid cleaning operations. This self-service approach reduces operational complexity while maintaining cleaning effectiveness.
3Reliability
If traditional clean-out methods are used, then debris removal is achieved, but the risk of stuck completion operations and maintenance requirements increase
Solution Approach 1:
The inverted reverse circulation approach prevents stuck completion operations by continuously moving debris upward before it can settle and cause obstructions. By flowing fluid upward from the lower end to the upper end, the system maintains constant debris transport, eliminating the risk of debris accumulation that leads to stuck completions and reducing maintenance requirements.
Solution Approach 2:
The hydraulic flow system continuously transports debris upward through the annulus, preventing debris settlement that could cause stuck operations. The wellbore fluid circulation creates a continuous conveyance mechanism that maintains smooth operation throughout the cleaning process, reducing the likelihood of completion issues and maintenance needs.
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 tool efficiently removes metallic and non-metallic debris, minimizes clean-out time, reduces maintenance, and prevents stuck completion operations by utilizing reverse circulation and magnetic attraction, improving flushing efficiency and initial filtration within the wellbore.
Implementation Method 1
at least one screen positioned in the inner volume and configured to catch one or more debris in the flow of the wellbore fluid circulated into the flow path through the fluid inlet
Implementation Method 2
at least one magnetic member mounted within the flow path and configured to magnetically attract at least a portion of the one or more debris
Data Source
AI summary
A downhole clean out tool includes a housing coupled to a downhole conveyance and defining an inner volume that includes a flow path that extends from an uphole end to a downhole end that includes a fluid inlet; a first flow port oriented towards the downhole end and configured to fluidly couple the flow path to an annulus of the wellbore through the housing; a seat formed in the housing and configured to receive a member inserted into the wellbore such that the flow of the wellbore fluid is diverted from the flow path, through the first flow port, to the annulus, and to the fluid inlet based on the member seated on the seat; at least one screen positioned in the inner volume; and a second flow port oriented towards the uphole end and configured to fluidly couple the flow path to the annulus of the wellbore.