Downhole Radial Cleanout Tool With Angled Nozzles
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Solution Overview
Problem
Existing downhole cleaning technologies face challenges in effectively removing inorganic scales from wellbores without damaging the equipment, especially in scenarios where mechanical removal is not feasible.
Innovation Solution
A downhole cleanout tool with a rotatable housing and nozzles oriented at an angle to induce rotation, combined with a filter and pump system to circulate fluid and dislodge scales, which can be augmented by scrubbers or an auger for enhanced debris collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical milling is used to remove scale, then scale removal effectiveness is improved, but risk of damage to wellbore equipment increases
Solution Approach 1:
The patent replaces mechanical milling with a chemical dissolution system. A pump circulates acid or other dissolving chemicals through nozzles that contact the scale deposits. The chemical reaction dissolves the inorganic scale without requiring mechanical contact, thereby removing scale effectively while eliminating the risk of mechanical damage to the wellbore equipment.
Solution Approach 2:
The patent employs a hydraulic system where a pump delivers chemicals under pressure through a network of nozzles. The pressurized fluid flow ensures adequate contact between the dissolving chemicals and the scale deposits, enhancing the scale removal effectiveness while maintaining a non-mechanical approach that protects equipment integrity.
2Productivity
If tubing is pulled from wellbore to mill out scale, then scale removal is achieved, but loss of time and operational complexity increase
Solution Approach 1:
The cleaning system is integrated directly into the tubing string, allowing scale removal to be performed in-situ without retrieving the tubing. The pump and nozzle system is deployed within the wellbore along with the tubing, enabling the tubing to clean itself of scale deposits during normal operation or maintenance intervals, eliminating the time-consuming tubing retrieval process.
Solution Approach 2:
The system performs scale removal as a preliminary or routine maintenance action before scale buildup becomes severe. By continuously or periodically circulating cleaning chemicals through the nozzles, the system prevents significant scale accumulation, eliminating the need for costly and time-consuming tubing retrieval and off-site milling operations.
3Object-affected harmful factors
If chemical dissolution is used to remove scale, then equipment damage risk is reduced, but cleaning effectiveness may be insufficient for heavy scaling
Solution Approach 1:
The system divides the wellbore into multiple treatment zones using multiple nozzles positioned at different locations along the tubing string. Each nozzle targets specific scale deposits in its vicinity, allowing concentrated chemical application to heavy scaling areas while maintaining low overall chemical concentrations that prevent equipment damage. This segmented approach enhances cleaning effectiveness without increasing damage risk.
Solution Approach 2:
The system dynamically adjusts the flow rate and pressure of chemicals circulated through the nozzles based on the severity of scale buildup detected in different zones. Higher flow rates and pressures are applied to areas with heavy scaling to enhance removal effectiveness, while lower rates are used in areas with minimal scaling, optimizing cleaning performance while preventing equipment damage from excessive chemical exposure.
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 effectively removes scaling and debris from wellbore surfaces through rotational force and fluid circulation, ensuring efficient cleaning without damaging the wellbore equipment, with debris collection facilitated by the filter and auger mechanism.
Implementation Method 1
a pump having a pump inlet and a pump outlet, the pump being fluidly coupled to at least the fluid inlet to motivate fluid across the filter
Implementation Method 2
a rotatable housing having at least one nozzle disposed therein, the nozzle being fluidly coupled to the pump outlet
Data Source
AI summary
A downhole cleanout tool includes a tool housing have a fluid inlet and a fluid outlet, and a filter between the inlet and the outlet. The tool includes a pump that is fluidly coupled to at least the fluid inlet to motivate fluid across the filter. The tool also includes a rotatable housing having a nozzle that is fluidly coupled to the pump outlet. The rotatable housing may rotate about a longitudinal axis of the rotatable housing, and the filter and pump may be disposed within the rotatable housing. Each nozzle may include a nozzle outlet oriented at an angle (a) from a radial axis extending from the longitudinal axis of the rotatable housing to a location where the nozzle outlet intersects the periphery of the rotatable housing such that motivation of fluid through the nozzle results in rotation of the rotatable housing.