Patent ID: 12215568

DETAILED DESCRIPTION

This disclosure describes an integrated wellbore scale remover and collector. The apparatus can be used to remove accumulated scale and debris from a tubing, liner, or casing installed in a well and collect the scale and debris in single runs or multi-trips. The apparatus can be deployed via slickline, coiled tubing, or drill pipe. The apparatus includes a rotating bit, a collection housing, a circulating plate assembly, and a guide. The apparatus can optionally include additional collection housings depending on the severity of scaling in the well. The rotating bit includes a plurality of blades, and each blade includes inserts that facilitate removal of scale/debris from an inner wall of a tubing as the bit rotates. The guide also includes a plurality of blades, and each blade includes inserts that facilitate removal of scale/debris from an inner wall of the tubing as the guide rotates. The collection housing and the circulating plate assembly define a volume available for accumulating scale/debris that has been removed from the inner wall of the tubing.

The subject matter described in this disclosure can be implemented in particular implementations, so as to realize one or more of the following advantages. The apparatuses, systems, and methods described here can be implemented to remove and collect scale and/or debris that has accumulated on the walls of tubulars (such as casing) installed in a wellbore. The apparatus can remove scale from a range of tubular sizes. The apparatuses, systems, and methods described here can maintain well integrity and may lengthen production lifetime of the well. The apparatus can be modularized, such that any of the components can be duplicated based on the characteristics of the well and target objectives for scale/debris removal. The apparatus can be coupled to and driven by a drill pipe or a thru-tubing motor for removal of scale/debris from especially small diameter tubulars. The apparatus can be quickly deployed in a single run or re-used in multiple trips for scale/debris removal and collection. The apparatuses, systems, and methods described here can remove and collect scale and/or debris from a wellbore without requiring mobilization of a workover rig. The apparatuses, systems, and methods described can be implemented to increase well productivity by maintaining a clear production path by removing scale and/or debris during a well lifecycle. The apparatuses, systems, and methods described can be implemented to reduce operational costs for maintaining well integrity.

FIG.1depicts an example well100constructed in accordance with the concepts herein. The well100extends from the surface106through the Earth108to one more subterranean zones of interest110(one shown). The well100enables access to the subterranean zones of interest110to allow recovery (that is, production) of fluids to the surface106(represented by flow arrows inFIG.1) and, in some implementations, additionally or alternatively allows fluids to be placed in the Earth108. In some implementations, the subterranean zone110is a formation within the Earth108defining a reservoir, but in other instances, the zone110can be multiple formations or a portion of a formation. The subterranean zone can include, for example, a formation, a portion of a formation, or multiple formations in a hydrocarbon-bearing reservoir from which recovery operations can be practiced to recover trapped hydrocarbons. In some implementations, the subterranean zone includes an underground formation of naturally fractured or porous rock containing hydrocarbons (for example, oil, gas, or both). In some implementations, the well can intersect other types of formations, including reservoirs that are not naturally fractured. For simplicity's sake, the well100is shown as a vertical well, but in other instances, the well100can be a deviated well with a wellbore deviated from vertical (for example, horizontal or slanted), the well100can include multiple bores forming a multilateral well (that is, a well having multiple lateral wells branching off another well or wells), or both.

In some implementations, the well100is a gas well that is used in producing hydrocarbon gas (such as natural gas) from the subterranean zones of interest110to the surface106. While termed a “gas well,” the well need not produce only dry gas, and may incidentally or in much smaller quantities, produce liquid including oil, water, or both. In some implementations, the well100is an oil well that is used in producing hydrocarbon liquid (such as crude oil) from the subterranean zones of interest110to the surface106. While termed an “oil well,” the well not need produce only hydrocarbon liquid, and may incidentally or in much smaller quantities, produce gas, water, or both. In some implementations, the production from the well100can be multiphase in any ratio. In some implementations, the production from the well100can produce mostly or entirely liquid at certain times and mostly or entirely gas at other times. For example, in certain types of wells it is common to produce water for a period of time to gain access to the gas in the subterranean zone. The concepts herein, though, are not limited in applicability to gas wells, oil wells, or even production wells, and could be used in wells for producing other gas or liquid resources or could be used in injection wells, disposal wells, or other types of wells used in placing fluids into the Earth.

The wellhead defines an attachment point for other equipment to be attached to the well100. For example,FIG.1shows well100being produced with a Christmas tree attached to the wellhead. The Christmas tree includes valves used to regulate flow into or out of the well100. The wellbore of the well100is typically, although not necessarily, cylindrical. All or a portion of the wellbore is lined with a tubing, such as casing112. The casing112connects with a wellhead at the surface106and extends downhole into the wellbore. The casing112operates to isolate the bore of the well100, defined in the cased portion of the well100by the inner bore116of the casing112, from the surrounding Earth108. The casing112can be formed of a single continuous tubing or multiple lengths of tubing joined (for example, threadedly) end-to-end. InFIG.1, the casing112is perforated in the subterranean zone of interest110to allow fluid communication between the subterranean zone of interest110and the bore116of the casing112. In particular, casing112is commercially produced in a number of common sizes specified by the American Petroleum Institute (the “API”), including 4½, 5, 5½, 6, 6⅝, 7, 7⅝, 7¾, 8⅝, 8¾, 9⅝, 9¾, 9⅞, 10¾, 11¾, 11⅞, 13⅜, 13½, 13⅝, 16, 18⅝, and 20 inches, and the API specifies internal diameters for each casing size. The apparatus200can be configured to fit in, and (as discussed in more detail below) in certain instances, scrape against the inner diameter of one of the specified API casing sizes. Of course, the apparatus200can be made to fit in and, in certain instances, scrape against other sizes of casing or tubing or otherwise scrape a wall of the well100. In some implementations, the casing112is omitted or ceases in the region of the subterranean zone of interest110. This portion of the well100without casing is often referred to as “open hole.”

In some cases, scale and/or debris accumulate in the well100, for example, on the wall(s) of tubulars disposed in the wellbore. An apparatus200can be deployed in the well100to remove and collect such scale and/or debris. For example, the apparatus200can scrape against one or more walls of the wellbore and store the scale and/or debris that has been removed from the one or more walls of the wellbore. An example of the apparatus200is shown inFIG.2Aand is described in more detail later.

FIG.2Ais a schematic diagram of an example apparatus200. The apparatus200can, for example, be used to remove and collect wellbore scale and/or debris from the well100. The apparatus200includes a scale removal head210, a scale collector220, a circulating plate assembly230, and a guide240. The apparatus200can be deployed in the well100, for example, via coiled tubing or drill pipe. In implementations in which the apparatus200is deployed via coiled tubing, the apparatus200can be rotated by a thru-tubing motor. In implementations in which the apparatus200is deployed via drill pipe201, the apparatus200can rotate with the drill pipe201. The apparatus200rotates as it travels downhole into the well100. The guide240can facilitate centralizing the apparatus200as it travels downhole into the well100. The guide240can include blades that scrape against a wall of the wellbore to remove scale and/or debris as the apparatus200rotates and travels downhole. The scale removal head210can include blades that scrape against the wall of the wellbore to remove scale and/or debris as the apparatus200rotates and travels downhole. The scale collector220and circulating plate assembly230can define a collection volume for storing the scale and/or debris that has been removed from the wall of the wellbore (for example, by the scale removal head210, by the guide240, or by both). The scale collector220and circulating plate assembly230can include slots and/or perforations that allow fluid to pass through the scale collector220and circulating plate assembly. Once deployed (run in hole (RIH)) to a desired depth, the apparatus200can be retrieved (for example, pulled out of hole (POOH)). In some implementations, the apparatus200is rotated while it is being POOH to remove scale and/or debris, for example, that may not have been removed while it was being RIH. Once the apparatus200has been retrieved at the surface, the collected scale and/or debris can be removed from the collection volume of the apparatus200and can be analyzed. The scale and/or debris can, for example, be analyzed to determine one or more characteristics about the well100.

The scale removal head210can be coupled to the drill pipe201. The scale collector220can be coupled to the scale removal head210opposite of the drill pipe201. The circulating plate assembly230can be coupled to the scale collector220opposite of the scale removal head210. The guide240can be coupled to the circulating plate assembly230opposite of the scale collector220. The scale removal head210can be coupled to the drill pipe201by a first threaded connection250a. The scale collector220can be coupled to the scale removal head210by a second threaded connection250b. The circulating plate assembly230can be coupled to the scale collector220by a third threaded connection250c. The guide240can be coupled to the circulating plate assembly230by a fourth threaded connection250d.

FIG.2Bis a schematic diagram of an example scale removal head210of the apparatus200. The scale removal head210is configured to couple to a drill pipe (such as the drill pipe201) or a thru-tubing motor that is coupled to a coiled tubing. Once coupled to the scale removal head210, the drill pipe201or the thru-tubing motor can rotate the apparatus200. For example, the apparatus200can rotate with the drill pipe201via the coupling between the scale removal head210and the drill pipe201. For example, the apparatus200can be rotated by the thru-tubing motor via the coupling between the scale removal head210and the thru-tubing motor. The scale removal head210includes blades212that are distributed around and extend radially outward from a surface of the scale removal head210. In some implementations, as shown inFIG.2B, the scale removal head210includes a rod211around which the blades212are distributed and from which the blades212extend radially outward. The blades212are configured to scrape against a wall of a wellbore (for example, a tubular installed in the well100) as the apparatus200rotates to remove scale and/or debris from the wall of the wellbore. In some implementations, as shown inFIG.2B, each of the blades212include inserts214that are disposed on surfaces of the blades212. The inserts214can facilitate removal of scale and/or debris as the blades212scrape against the wall of the wellbore. For example, the blades212and the inserts214can be cooperatively configured to scrape against the wall of the wellbore to remove scale and/or debris from the wall of the wellbore in response to rotation of the apparatus200. In some implementations, the rod211includes threaded ends211a,211b. The rod211can be coupled to the drill pipe201or thru-tubing motor via a threaded connection by any of the threaded ends211a,211b. For example, the threaded end211aof the scale removal head210can be coupled to the drill pipe201or the thru-tubing motor to form the threaded connection250a.

FIG.2Cis a schematic diagram of an example scale collector220of the apparatus200. The scale collector220is configured to couple to the scale removal head210. Once coupled to the scale removal head210, the scale collector220can rotate with the scale removal head210. The scale collector220includes a slotted chamber222. In some implementations, as shown inFIG.2C, the scale collector220includes a rod221, and the slotted chamber222surrounds (for example, encompasses) the rod221. The scale collector220defines a first inner region225awithin the slotted chamber222. In some implementations, the first inner region225ais defined as the annulus between the rod221and the slotted chamber222. The slotted chamber222defines slots223through which fluid can pass through the slotted chamber222. The slots223can be sized to prevent scale and/or debris of a certain size (or larger) cannot pass through the slots223. In some implementations, the slots223are at least about 1 millimeter (mm) wide, at least about 2 mm wide, or at least about 3 mm wide. For example, the slots223are in a range of from about 1 mm to about 5 mm, from about 2 mm to about 4 mm, or about 2 mm to about 3 mm. In some implementations, the rod221includes threaded ends221a,221b. The rod221can be coupled to the rod211of the scale removal head210via a threaded connection by any of the threaded ends221a,221b. For example, the threaded end221aof the scale collector220can be coupled to the threaded end211bof the scale removal head210to form the threaded connection250b.

FIG.2Dis a schematic diagram of an example circulating plate assembly230of the apparatus200. The circulating plate assembly230is configured to couple to the scale collector220. Once coupled to the scale collector220, the circulating plate assembly230can rotate with the scale collector220. The circulating plate assembly230includes a pipe232. The pipe232includes an open end232aand a perforated end232b. The perforated end232bis opposite the open end232a. The perforated end232bdefines perforations233through which fluid can pass through the pipe232. The perforations233can be sized to prevent scale and/or debris of a certain size (or larger) cannot pass through the perforations233. In some implementations, the perforations233have diameters that are at least about 1 mm, at least about 2 mm, or at least about 3 mm. For example, the perforations233have diameters that are in a range of from about 1 mm to about 5 mm, from about 2 mm to about 4 mm, or about 2 mm to about 3 mm. In some implementations, as shown inFIG.2D, the circulating plate assembly230includes a rod231, and the pipe surrounds the rod231. The circulating plate assembly230defines a second inner region225bwithin the pipe232. In some implementations, the second inner region225bis defined as the annulus between the rod231and the pipe232. The first inner region225a(defined by the scale collector220) and the second inner region225b(defined by the circulating plate assembly230) together define a collection volume225for accumulating and storing scale and/or debris that has been removed from the wall of the wellbore. In some implementations, the rod231includes threaded ends232a,232b. The rod231can be coupled to the rod221of the scale collector220via a threaded connection by any of the threaded ends231a,231b. For example, the threaded end231aof the circulating plate assembly230can be coupled to the threaded end221bof the scale collector220to form the threaded connection250c. In some implementations, the open end232aof the pipe232is configured to couple to the slotted chamber222of the scale collector220that is coupled to the circulating plate assembly230.

FIG.2Eis a schematic diagram of an example guide240of the apparatus200. The guide240is configured to couple to the circulating plate assembly230. Once coupled to the circulating plate assembly230, the guide240can rotate with the circulating plate assembly230. The guide240includes blades242that are distributed around and extend radially outward from a surface of the guide240. In some implementations, as shown inFIG.2E, the guide240includes a body241around which the blades242are distributed and from which the blades242extend radially outward. The body241can, for example, be shaped to facilitate the centralizing function of the guide240. For example, the body241can be shaped similarly to an ellipsoid, which may better facilitate the centralizing function of the guide240in comparison to a rod. The blades242are configured to scrape against the wall of the wellbore as the apparatus200rotates to remove scale and/or debris from the wall of the wellbore. In some implementations, as shown inFIG.2E, each of the blades242include inserts244that are disposed on surfaces of the blades242. The inserts244can facilitate removal of scale and/or debris as the blades242scrape against the wall of the wellbore. For example, the blades242and the inserts244can be cooperatively configured to scrape against the wall of the wellbore to remove scale and/or debris from the wall of the wellbore in response to rotation of the apparatus200. Thus, both the scale removal head210and the guide240can work together to remove scale and/or debris from the wall of the wellbore. For example, the guide240may remove scale and/or debris from the wall of the wellbore that the scale removal head210might have missed. For example, the scale removal head210may remove scale and/or debris from the wall of the wellbore that the guide240might have missed. In some implementations, the rod241includes a threaded end241. The rod241can be coupled to the circulating plate assembly230via a threaded connection by the threaded end241a. For example, the threaded end241aof the guide240can be coupled to the threaded end231bof the circulating plate assembly230to form the threaded connection250d.

The guide240can include a jet nozzle246. In some implementations, the jet nozzle246is opposite the threaded end241a. The jet nozzle246can be configured to circulate fluid (such as a drilling fluid) through the wellbore. Circulating fluid through the wellbore by the jet nozzle246can facilitate travel of the apparatus200through the wellbore. Circulating fluid through the wellbore by the jet nozzle246can facilitate removal of scale and/or debris from the wall of the wellbore as the apparatus200rotates and travels through the wellbore.

In some implementations, the blades242of the guide240are substantially the same as the blades212of the scale removal head210. In some implementations, the blades242of the guide240are different from the blades212of the scale removal head210. In some implementations, the inserts244of the guide240are substantially the same as the inserts214of the scale removal head210. In some implementations, the inserts244of the guide240are different from the inserts214of the scale removal head210.

FIG.3is a schematic diagram of an example apparatus300. The apparatus300can be substantially similar to the apparatus200and can include the same or substantially similar components of the apparatus200(such as the scale removal head210, the scale collector220, the circulating plate assembly230, and the guide240). The apparatus300can, for example, be used to remove and collect wellbore scale and debris from the well100. The apparatus300can be coupled to a thru-tubing motor303that is coupled to a coiled tubing301. For example, the scale removal head210is coupled to the thru-tubing motor303. The thru-tubing motor303can be configured to rotate the apparatus300.

In some implementations, as shown inFIG.3, the apparatus300includes multiple scale collectors220. Including multiple scale collectors can be useful for removing and collecting larger amounts of scale and/or debris from the well100. Although shown inFIG.3as including three scale collectors (220a,220b,220c), the apparatus300can include fewer scale collectors220(for example, one or two) or more scale collectors220(for example, four, five, or more than five). In some implementations, as shown inFIG.3, the scale collectors220are consecutive and coupled end-to-end. In some implementations, the scale collectors220can be separated by a different component of the apparatus300(such as the scale removal head210or the circulating plate assembly230). In some implementations, the apparatus300includes multiple implementations of any of the components of the apparatus200(for example, multiple scale removal heads210, multiple scale collectors220, multiple circulating plate assemblies230, multiple guides240, or any combination of these). In some implementations, the apparatus300includes multiple implementations of the apparatus200. For example, the apparatus300can include two or more implementations of the apparatus200coupled end-to-end.

FIG.4is a flow chart of an example method400for removing and collecting wellbore scale and debris, for example, from the well100. Any of the apparatuses200or300can, for example, implement method400. For simplicity and clarity, the description of the method400in this paragraph is described in relation to apparatus200(although apparatus300can optionally be used instead). At block402, the apparatus200is rotated. The apparatus200being rotated at block402is disposed within a tubular (for example, a production tubing or the casing112) installed in a wellbore (for example, the wellbore of the well100). At block404, fluid is circulated through the wellbore by a jet nozzle (such as the jet nozzle246) of the guide240. In response to rotating the apparatus200at block402and circulating the fluid at block404, the apparatus200is centralized within the tubular by the guide240at block406. Rotating the apparatus200at block402and circulating the fluid at block404facilitates travel of the apparatus200through the tubular. In response to rotating the apparatus200at block402and circulating the fluid at block404, a first plurality of blades (such as the blades212) of the scale removal head210scrapes against a wall of the tubular to remove scale and/or debris from the wall of the tubular at block408. In response to rotating the apparatus200at block402and circulating the fluid at block404, a second plurality of blades (such as the blades242) of the guide240scrapes against the wall of the tubular to remove scale and/or debris from the wall of the tubular at block410. At block412, the scale and/or debris that have been removed from the wall of the tubular is collected within a collection volume (such as the collection volume225) of the apparatus200. As described previously, the collection volume225is cooperatively defined by the slotted chamber222of the scale collector220that is coupled to the pipe232of the circulating plate assembly230.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.

As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate.

Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described components and systems can generally be integrated together or packaged into multiple products.

Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure.