Laser Mandrel for In-Situ Scale Removal in Production Strings

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Solution Overview

Problem

Current methods for managing scale in oil well production equipment, such as chemical inhibition and removal solutions, require frequent operations, leading to operational and financial challenges due to resource availability and production losses, especially in pre-salt wells with carbonate formations where scale formation can block equipment.

Innovation Solution

A laser mandrel is installed in the production string below intelligent completion valves, using fiber optic cables, electrical cables, collimators, and laser diodes to prevent and remove scale by generating laser radiation that dissolves calcium carbonate through thermal disintegration, maintaining equipment cleanliness and reducing the need for conventional scale management processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chemical inhibition or removal solutions are used to manage scale, then scale formation is controlled, but frequent operations are required leading to production losses and operational challenges

Engineering Contradiction:

Improvescale control effectivenessVSAvoidproduction continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces chemical inhibition and removal methods with a laser-based system. The laser mandrel uses optical energy to prevent and remove scale through thermal effects, eliminating the need for chemical treatments and associated frequent operational interventions that cause production losses.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser mandrel is designed to be run through the production string continuously or periodically without requiring production shutdowns. The system maintains scale-free conditions through continuous laser irradiation during normal production operations, ensuring uninterrupted production while effectively managing scale.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If conventional scale removal operations are performed, then scale is removed from equipment, but operational costs and financial losses increase due to rig availability and production stoppage

Engineering Contradiction:

Improveequipment functionalityVSAvoidproduction downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The laser mandrel system is deployed through the existing production string using the well's own production flow, eliminating the need for external rigs or stimulation boats. The system serves itself by utilizing the production environment to deliver laser treatment, avoiding costly external resource mobilization and production shutdowns.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces heavy mechanical intervention systems (rigs, stimulation boats) with a compact laser delivery system that can be inserted through the production string. This substitution eliminates the need for expensive external equipment and associated production stoppages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If chemical inhibitors are used in the reservoir, then scale formation is prevented, but chemical costs and environmental concerns increase

Engineering Contradiction:

Improvescale preventionVSAvoidchemical environmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical inhibition methods with a physical laser-based system. The laser mandrel uses optical energy to prevent and remove scale through thermal effects, eliminating the need for chemical treatments and their associated environmental concerns and costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 laser mandrel effectively prevents scale formation and enhances the efficiency of scale removal, reducing the frequency of maintenance operations, minimizing production losses, and ensuring continuous well production while adhering to environmental and safety guidelines.

Implementation Method 1

using fiber optic cables, electrical cables, collimators, and laser diodes to prevent and remove scale by generating laser radiation that dissolves calcium carbonate through thermal disintegration

Methodology Applied

Scientific EffectThermal disintegration: Heating

Data Source

PatentUS11982156B2Laser mandrel for removal of scale in production equipment

Publication Date: 2024.05.14 PETROLEO BRASILEIRO SA PETROBRAS

AI summary

The present invention presents a laser mandrel (9) capable of being installed in the production string, in a position below the ICVs valves (2 and 4), to be used in a first moment aiming at preventing the formation of scale in the ICVs valves (2 and 4), and, in a second moment, for the removal of scale from the production string (1).The laser mandrel (9) of this invention is provided with fiber optic cable (5), electrical cable (6), collimators (7), and laser diodes (8). It can be applied to prevent damage to well strings with electric intelligent completion, in case there is a failure in the chemical injection system installed in the string. It also makes possible the improvement of the technique aiming at the inhibition of inorganic depositions. Furthermore, it has a significantly lower cost than the conventional squeeze and/or removal, because once it is installed in the string, it allows the management of scale.