Downhole Tool Conditioning With Sealed End Caps
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Solution Overview
Problem
Downhole tools accumulate deposits and corrosion due to wellbore fluids during use, leading to tool failure and significant downtime upon redeployment, as current methods do not effectively clean or condition the tools between deployments.
Innovation Solution
A method and system for exposing downhole tools to a conditioning fluid while out of service, using caps to seal the tool ends and introduce conditioning fluid through the inner bore to remove deposits and prevent corrosion, with caps designed for different tool connections and materials to protect and facilitate handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If downhole tools are removed from the wellbore and stored on the surface, then the tools can be inspected and maintained, but deposits form inside and on the tool when the fluid dries, causing corrosion and jamming of moving parts
Solution Approach 1:
The patent applies preliminary action by introducing conditioning fluid into the downhole tool before it is fully removed from service, and maintaining that fluid in the tool during storage and transport. This preliminary conditioning prevents deposits from forming in the first place, rather than attempting to remove them later. The fluid is introduced through ports in the tool housing while the tool is still accessible, and the tool is then sealed and stored with the conditioning fluid already in place, preventing corrosion and deposit formation during the storage period.
Solution Approach 2:
The conditioning fluid acts as an intermediary substance between the downhole tool and the harmful wellbore fluid residues. This fluid displaces and isolates the tool surfaces from corrosive deposits, creating a protective barrier. The conditioning fluid mediates the interaction between the tool and environmental contaminants, preventing direct contact between harmful substances and critical tool surfaces during storage and transport.
2Productivity
If the tool is not cleaned between deployments, then maintenance time is reduced, but deposits accumulate leading to tool failure and significant downtime upon redeployment
Solution Approach 1:
The system performs preliminary conditioning of the tool by introducing conditioning fluid into the tool's internal passages and cavities before the tool is fully decommissioned. This preliminary treatment prevents deposit accumulation during storage, eliminating the need for time-consuming cleaning operations between deployments. The conditioning fluid remains in the tool during storage, continuously preventing deposits from forming, thereby readying the tool for immediate redeployment without maintenance downtime.
Solution Approach 2:
The conditioning fluid maintains a continuous protective action within the tool during storage and transport. Rather than performing discrete cleaning operations, the system establishes a continuous state of protection where the conditioning fluid constantly prevents deposit formation on tool surfaces. This continuous protective action ensures the tool remains in serviceable condition throughout the entire storage period, enabling seamless transition to the next deployment without interruption for maintenance.
3Reliability
If caps are used to seal the tool ends and introduce conditioning fluid, then the tool is protected from further fluid exposure, but the device complexity increases
Solution Approach 1:
The cap assembly serves multiple functions simultaneously: it seals the tool ends to prevent further fluid ingress, introduces conditioning fluid into the tool's internal passages, and provides structural support during handling. By combining sealing, fluid introduction, and structural functions into a single multi-functional component, the system achieves comprehensive tool protection without proportionally increasing complexity. The cap is designed to perform all necessary operations during the conditioning process, eliminating the need for separate sealing and fluid introduction mechanisms.
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
Prevents tool degradation and failure by minimizing exposure to wellbore fluids, reducing maintenance time, and ensuring tools are ready for immediate redeployment with minimal downtime and resource use.
Implementation Method 1
exposing a downhole tool to a conditioning fluid while the downhole tool is out of service... to remove deposits
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
A wellbore tool is conditioned between downhole deployments with a substantially continuous application of a conditioning fluid within the tool. Selectively removable caps connect to ends of the tool after its removal from the wellbore. If the tool is part of a downhole string, the caps are added after the tool is decoupled from the remainder of the string. The conditioning fluid is introduced into the tool through a fitting on one of the end caps; and while a fitting on the other end cap is opened to vent fluids resident within the tool. The caps are in sealing contact with a housing of the tool to retain the conditioning fluid inside the tool. A fluid supply system at the well site provides the conditioning fluid. Example conditioning fluids include a fracturing fluid, a completion fluid, a diluent, a solubilizing agent, an anti-scaling agent, a pH buffer, a liquid freezing point depressant, corrosion and oxidation inhibitors, oxygen scavengers, biocides, surfactants, and combinations thereof.