United States Patent: (10) Patent No.: (45) Date of Patent

USOO66O7607B2
(12) United States Patent (10) Patent No.: US 6,607,607 B2

Walker et al. (45) Date of Patent: Aug. 19, 2003
(54) COILED TUBING WELLBORE CLEANOUT 5.984.011 A 11/1999 Misselbrook et al.

6,029,746 A 2/2000 Dodd
(75) Inventors: Scott A. Walker, Calgary (CA); Jeff 6,065,540 A 5/2000 Thomeer et al.
Li, Calgary (CA); Graham Wilde, 6,602,311 5/2000 Johnson et al.
Calgary (CA) 6,073,696 A 6/2000 Ellis
6,085,844 A 7/2000 Palmer et al.
6,138,757 A 10/2000 Latos et al.
(73) Assignee: BJ Services Company, Houston, TX 6,170,577 B1 1/2001 Noles, Jr. et al.
(US)
FOREIGN PATENT DOCUMENTS
(*) Notice: Subject to any disclaimer, the term of this GB 92.17186.7 12/1992
patent is extended or adjusted under 35 GB 99.13998.2 12/1999
U.S.C. 154(b) by 40 days. WO WO 99/49 181 9/1999
(21) Appl. No.: 09/799,990 OTHER PUBLICATIONS
(22) Filed: Mar. 6, 2001 Curtis G. Blount, “Remote Arctic Locations” (No Date
(65) Prior Publication Data
Available).
BJ Services Company, “Fill Removal”, Chapter 4CTU-202
US 2003/0056811A1 Mar. 27, 2003 Manual Jan. 05,2000.
Alexander Sas-Jaworsky II, “Coiled Tubing... Operations
Related U.S. Application Data and Services”, Part 4 (No Data Available).
(60) Provisional application No. 60/200,241, filed on Apr. 28, L. J. Leising/I. C. Walton, “Cuttings Transport Problems
2000. and Solutions in Coiled Tubing Drilling” IADC/SPE 39300
(51) Int. Cl." .................................................. B08B 7/04 Mar. 03, 1998.
Ian C. Walton/Hongren Gu, “Hydraulics Design in Coiled
(52) U.S. Cl. ..................... 134/18; 134/22.1; 134/22.11; Tubing Drilling”, SPE 36349, Feb. 28, 1995.
134/22.12; 134/22.18; 134/23; 134/24; J. Li/S. Walker, “Sensitivity Analysis of Hole Cleaning
134/34; 134/166 C; 134/167 C; 134/168 C; Parameters in Directional Wells”, SPE 54498, May 25,
134/169 C; 166/311; 166/312; 166/369; 1999.
166/370; 166/372; 166/222; 175/61; 175/62; S. Walker/J. Li, “The Effects of Particle Size, Fluid Rheol
175/92; 175/94; 175/215; 175/232 ogy, and Pipe Eccentricity On Cuttings Transport”, SPE
(58) Field of Search ....................... 134/18, 22.1, 22.11, 60755, Apr. 05, 2000.
134/22.12, 22.18, 23, 24, 34, 166 C, 167 C,
168 C, 169 C; 166/311, 312,369, 370, * cited by examiner
372, 222; 175/61, 62, 92, 94, 215, 232 Primary Examiner Randy Gulakowski
(56) References Cited ASSistant Examiner M. Kornakov
(74) Attorney, Agent, or Firm-Howrey Simon Arnold &
U.S. PATENT DOCUMENTS White, LLP
3,912,173 A 10/1975 Robichaux (57) ABSTRACT
4,441,557. A 4/1984 Zublin
4,744.420 A 5/1988 Patterson et al. Method and apparatus for Substantially cleaning fill from a
4909,325 A 3/1990 Hopmann borehole, variously including in preferred embodiments
5,033,545. A 7/1991 Sudol ......................... 166/312 disturbing, particulate solids of fill while RIH, entraining
5,086,842 A 2/1992 Cholet particulates while POOH, jetting downhole while RIH and
5,280.825. A 1/1994 Cholet jetting uphole while POOH, and controlling at least one of
5,314,545 A 5/1994 Folts et al. a pump rate regime or a POOH rate regime.
5,392,862 A 2/1995 Swearingen
5,447.200 A 9/1995 Dedora et al.
5,865,249 A 2/1999 Gipson et al. 48 Claims, 17 Drawing Sheets
U.S. Patent Aug. 19, 2003 Sheet 1 of 17 US 6,607,607 B2
F/G, 1
(PRIOR ART)
F/G 2
(PR/OR ART)
F/G3
(PR/OR ART)
F/G, 4.
(Prior Art)
FIG. 5
80
(Prior Art)
Z ?š No.te
SË
§ GÈ
&
if
?S SË
FIG. 8
O
100 NCRON 50MCROW -20MCRON 420MCROW420NCRONiZ00MICRON
SAND W idoNESH) (40 MESH) zomesi) (40 ESH) i2MESH
WAER" CANEWS, ARGoikop;5
WATER WATER 20, GE IN WATER WATER
| 5),
U.S. Patent Aug. 19, 2003 Sheet 10 Of 17 US 6,607,607 B2
FIG 2
F/G, 13
WIPER SPEED
NSN NaNYKZ \ K'idi

YA\NN
K. ( (3
(N(2 VELOCITY
OOO
X. ^
R
x REMOVAL
(%)
1OO
F/G, 14
C VSUPER = 5 m/min O VSUPER =20m/min
0 VSUPER = 10 m/min O VSUPER =30 m/min
v VSUPER = 15 m/min O VSUPER = 40m/min
- - - I -
80
6O
40
O 5 10 15 2O 25 3O 35 AO
WIPER IR/P SPEED (DIMENSIONLESS) --
F/G, 15
| -
NOT COMPLETLY
CLEANED OUT
1N - SITU L/QUID VELOCITY --
FIG 16
l 120
N
100 - 300 LPM WATER/
s S 7rnrn ROCK
U 300 LPM
S 80 WATER/CARBO----
S 300 LPM LITE
l WATE/O. 75rnrn ROCK
S 60 pol PM WATER/0.75nnnn ROCK "T
S 40
N
100 LPM WATER/CARBOLITE
-----------------
100 LPM
Q 7rnn ROCK N |
U
S
20 t - --
S O
O 2 4
N6 8 10 12
WIPER TR/P SPEEE) (rn/rn in ) -a-
F/G 17 C--O 327 LPM WATER A-A 204 LPM HEC

O-O 364 LPM XANVIS O---O 114 LPM WATER
V-7 352 LPM HEC X---X 113 LPM XAN V/S
C--O 202 LPM WAIER O-O 107 LPM HEC
O-O 200 LPM XANV/S
80
60
4O
O 2 4 6 6 10 12 14, 16
WIPER TRIPSPEED (rn/rnin) --
F/G, 18
C-C 364 LPM XANVIS di) 65° V-7 204 LPM XANVIS di) 90
C--O 345 LPM XANVIS d) 90° O-O 113 LPM XANVIS d) 65
120 A-\, 2OOLPM XAN V/S d) 65° O--O 111 LPM XANVIS d)909
-T-
se -
80 -
6O
4O w
2O
O
O 2 4 6 8 10 12 l4 16
WIPER TRIPSPEED (rn/rnin) --
U.S. Patent Aug. 19, 2003 Sheet 16 0f 17 US 6,607,607 B2
FIG. 19
100 LPM WATER/ 100 PM WATER

100 LPM AIR -
O 5 10 15 20 25
WIPER TRIPSPEED (m/min) --
F/G2O
300 LPM - I -
WATER RATE
O 10 2O 3O 40 50 60 70 80
GAS VOID FRACTION (/) --
US 6,607,607 B2
1 2
COILED TUBING WELLBORE CLEANOUT cleanouts are not as Simple as might be expected, the usual
definition of “clean” is likely to be set by local field
This application claims priority based on provisional experience and may not represent what can or should be
application Serial No. 60/200,241 filed Apr. 28, 2000. achieved. A third problem has been determining the question
of how clean is clean enough. An ineffective or incomplete
FIELD OF THE INVENTION well cleanout results in shorter production intervals between
This invention is related to cleaning a wellbore of fill, and cleanouts and increased maintenance.
more particularly, to cleaning an oil/gas wellbore of Sub It costs more to re-do a job than to do it right the first time.
Stantial fill using coiled tubing. The object of the instant invention is to ensure that owners/
operators do not incur the costs of recleaning their wells for
BACKGROUND OF THE INVENTION as long as possible, prolonging well production and main
Solutions exist to an analogous problem in a related field, taining wireline accessibility. A well that requires a cleanout
the problem of cuttings beds in the field of coiled tubing every 12 months between poorly designed, incomplete jobs
drilling in deviated wells, a field employing different equip may last 24 months between properly designed cleanout
ment in different circumstances. The Solutions are similar 15 jobs.
but have important distinctions with regard to the instant Unless a well is a vertical hole (<35 deviation) with a
invention. Some, though not all, practitioners when drilling generously sized completion assembly and moderate bottom
with coiled tubing (CT) in deviated wells cleanout cutting hole pressure, cleanout procedures according to conven
beds that develop by a wiper trip. Cuttings in a deviated well tional practices are likely to leave significant debris or fill in
periodically form beds under CT, uphole of the drilling, the hole. One further object of the instant invention is to
notwithstanding the efforts to circulate out all of the cuttings offer a comprehensive engineered approach to CT cleanouts,
with the drilling fluid. Some practitioners periodically dis targeted to Substantially clean a hole of fill in one trip.
turb and,entrain and circulate out their cuttings beds by SUMMARY OF THE INVENTION
dragging the bit and its assembly back uphole, while circu 25
lating. This bit wiper trip is a relatively short trip through a In one preferred embodiment the invention includes a
portion of the borehole and is interspersed, of course, with method for cleaning fill from a borehole comprising dis
periods of drilling where more cuttings are created and are turbing particulate Solids by running in hole, in typical cases
(largely) transported out by the circulation of the drilling through substantial fill, with a coiled tubing assembly while
fluid. The need for a wiper trip is determined by gauging circulating at least one cleanout fluid through a nozzle
when a cuttings bed is causing too much drag or friction on having a jetting action directed downhole. This invention
the coiled tubing such that it is difficult to lay weight on the may include creating particulate entrainment by pulling out
bit. of hole while circulating at least one cleanout fluid through
The bit wiper trip typically does not comprise a full a nozzle having a jetting action directed uphole. The inven
pulling out of the hole (“POOH') but rather for only 100 feet 35 tion may include controlling at least one of 1) the pump rate
or So, progressively increasing as more hole is drilled. The of the cleanout fluid and/or 2) the coiled tubing assembly
trip length may increase as the hole gets deeper. POOH rates pull out rate Such that Substantially all particulate Solids are
with the bit wiper trip are not known to be scientifically maintained uphole of an end of the coiled tubing assembly
Selected using computer modeling. This is not a workover during pull out. The invention may also include controlling
Situation that targets Substantial cleaning of fill in one wiper 40 the POOH rate so that equilibrium sand beds are established
trip. A bit and its assembly comprise a costly and elaborate uphole of the jets, if or to the extent that such beds were not
downhole tool for a wiper trip. established during running in hole (RIH).
Key distinctions between the instant invention and peri The invention can include in one embodiment a method
odic bit wiper trips include, firstly, the use herein of a far leSS for cleaning fill from a borehole in one wiper trip comprising
expensive jetting nozzle as compared to an expensive drill 45 jetting downhole, through a nozzle connected to coiled
ing bit, motor and associated assemblies, to disturb and tubing, at least one cleanout fluid during at least a portion of
entrain the fill. A Second distinction is the use of rearward running downhole. The invention can include jetting uphole
facing jets while POOH by the instant invention. A third key through a nozzle connected to the coiled tubing at least one
distinction is the engineered Selection of pump rates and/or cleanout fluid during at least a portion of pulling out of hole.
RIH rates and/or POOH rates, based on computer modeling, 50 The invention can include pumping during at least a portion
in order to target a cleanout of the hole in one trip. of pulling out of hole at least one cleanout fluid at a Selected
In regard to the computer modeling of Wells, in general, pump rate regime, pulling out of hole for at least a Section
and further in regard to the modeling of cleanouts perse, it of the borehole at a Selected pulling rate regime, and
has been known in the art to model a Solids/cuttings bed substantially cleaning the borehole of fill. Preferably the
cleanout by modeling circulation in a deviated hole contain 55 invention includes high energy jetting downhole and low
ing coiled tubing. To the inventors best knowledge, energy jetting uphole.
however, it has not been known to model two phase flow in The invention can include a method for cleaning a bore
these circumstances nor to model the effects of a dynamic hole of fill comprising Sweeping back at least one uphole
wiper trip while jetting. In particular it has not been known directed jet connected to coiled tubing while pulling out of
to model a wiper trip involving POOH with a nozzle having 60 hole at a Selected pulling rate regime. This invention can
uphole pointing jets. include pumping at least one cleanout fluid at a Selected
Turning to the well cleanout industry in particular, one pump rate regime down the coiled tubing and out the at least
problem that has historically faced well owners and opera one jet during at least a portion of pulling out of hole. The
tors is the question of whether a well is clean in fact when, invention can also include Selecting, by computer modeling,
during a cleanout, the well is flowing clean with the work 65 at least one of 1) pump rate regime and/or 2) pull out of hole
over coiled tubing (CT) at target depth (TD). A second rate regime Such that one Sweep Substantially cleans the
problem: is that since many of the so-called “routine” borehole of fill.
US 6,607,607 B2
3 4
The invention can include a method for cleaning out a FIG. 8 is a table that illustrates particle vertical fall rates.
borehole of particulate matter comprising modeling a FIG. 9 illustrates advantages, disadvantages and applica
cleanout, taking into account a plurality of well parameters tions for typical cleanout fluids.
and a plurality of equipment parameters, to produce at least FIG. 10 illustrate. preferred cleanout nozzles of the instant
one running parameter regime predicted to clean to a given invention.
degree the borehole with one wiper trip of coiled tubing, the FIG. 11 is a scheme for a cuttings transport flow loop for
coiled tubing attached to at least one forward jet and one experiments related to the instant invention.
reverse jet. This invention can include cleaning the borehole
to obtain the given degree of cleanout in one wiper trip with FIG. 12 is a photo of horizontal transport flow loop used
the coiled tubing while implementing at least one produced 1O in experiments relating to the instant invention.
running parameter regime. FIG. 13 is a chart illustrating the effect of wiper trips
The invention can include apparatus for cleaning fill from Speed and flow rate on hole cleaning efficiency in experi
a borehole in one wiper trip comprising a nozzle adapted to ments relating to the instant invention.
be attached to coiled tubing, the nozzle having at least one FIG. 14 is a chart illustrating hole cleaning efficiency for
high-energy jet directed downhole, at least one low energy 15 water at 90 with a particular nozzle Selection, as relating to
jet directed uphole and means for Switching in the nozzle experiments in connection with the instant invention.
fluid flow from the at least one high energy jet to the at least FIG. 15 illustrates effective hole cleaning; volume with
one low energy jet. different nozzles types for water at a horizontal wellbore in
The invention can include a method for cleaning fill from experiments associated with the instant invention.
a borehole in one wiper trip comprising computer modeling FIG. 16 illustrates effective sand type on hole cleaning
of solids bed transport in a deviated borehole while pulling efficiency with cleanout fluids at a horizontal wellbore in
out of hole with coiled tubing according to pulling out rate experiments associated with the instant invention.
regime and while jetting uphole at least one cleanout fluid FIG. 17 illustrates the effective fluid type on the hole
according to a cleanout fluid pump rate regime. 25 cleaning efficiency with particular cleanout fluids in a devi
In preferred embodiments the invention includes tool ated wellbore in experiments associated with the instant
design and methodology for coiled tubing in Vertical, invention.
deviated, and horizontal wells. The invention includes run FIG. 18 illustrates the effects of deviation angle on the
ning coiled tubing into the well while circulating water, hole cleaning efficiency with fluids and nozzles in experi
gelled liquids or multiphase fluids using a nozzle. With a ments associated with the instant invention.
“high energy' jetting action pointing forwards down the
well to Stir up the particulate Solids and allow the coiled FIG. 19 illustrates the effects of gas phase on the cleaning
tubing to reach a target depth or bottom of the well. When efficiency for particulate fill in a particulate nozzle in experi
ments associated with the instant invention.
the bottom or desired depth is reached, the invention
includes reversing the jetting direction of the nozzle to point 35
FIG. 20 illustrates the effects of gas volume fraction on
upward (up the wellbore) while circulating water, gelled wiper trip Speed for particulate fill for a particulate nozzle in
liquids or multiphase fluids using a low energy Vortex nozzle a deviated well in experiments associated with the instant
that will create a particle re-entrainment action to enhance invention.
agitation of the Solids and then entrain the Solids in Suspen FIGS. 21A and 21B illustrate methodologies associated
sion for transport out of the wellbore while pulling the coiled 40
with the instant invention.
tubing out of the hole. The reverse jetting action along with
a controlled pump rate and wiper trip speed can produce a DETAILED DESCRIPTION OF PREFERRED
Solids transport action which cleans the hole completely by EMBODIMENTS
keeping the cuttings in front (upward) of the end of the The phrase “well parameters' as used herein can include
coiled tubing in continuous agitation. The low energy 45 borehole parameters, fill parameters and production param
nozzles have a low preSSure drop which allows for higher eters. Borehole parameters could include well geometry and
flow rates which results in improved cleanout efficiency. completion geometry. Fill parameters might include particle
This method and tool is more efficient than existing methods size, particle shape, particle density, particle compactness
Since the proceSS may be limited to one pass or Sweep with and particle Volume. Production parameters might include
the option of resetting the tool for repeated cycles if prob 50 whether a borehole is in an overbalanced, balanced or
lems are encountered. underbalanced condition, whether the borehole is being
BRIEF DESCRIPTION OF THE DRAWINGS
produced or is shut in or is an injection well, the bottomhole
pressure (BHP) and/or the bottomhole temperature (BHT).
A better understanding of the present invention can be Equipment parameters could include the type of nozzle(s),
obtained when the following detailed description of the 55 the energy and direction of nozzle jet(s), the diameter and
preferred embodiments are considered in conjunction with type of the coiled tubing and the choice of a cleanout fluid
the following drawings, in which: or fluids. Cleanout fluids are typically water, brine, gels,
FIGS. 1, 2 and 3 illustrate a technique of the prior art that polymers, oils, foams and gases, including mixtures of the
might unsuccessfully cleanout borehole of Substantial fill. above. Two phase flow indicates flow that includes a Sig
FIG. 4 illustrates a vertical well with Substantial fill.
60 nificant amount of liquid and gas.
A running parameter combination includes at least one of
FIG. 5 is a chart that illustrates the time to transport a pump rate regime, fixed or variable, for cleanout fluid(s)
particles 1000 feet vertically with different cleanout fluids. and a POOH rate regime, fixed or variable. A pump rate
FIG. 6 illustrates the forces on a particle in a deviated regime possibly extends to include a regime for Several
well. 65 cleanout fluids, if a plurality of fluids are used, Simulta
FIG. 7 illustrates the formation of a sand bed around neously or Sequentially, and to include an amount of nitro
tubing in the annulus of deviated tubing. gen or gas, if any used, and its timing. A Sweep rate regime
US 6,607,607 B2
S 6
for coiled tubing includes at least a pull out of hole (POOH) Disturbing particulate Solids of fill indicates disturbing to
rate. Such rates could be variable or fixed and do not an extent of Significantly redistributing the fill. This is more
necessarily rule out Stops or discontinuities or interruptions. than a trivial or minor or Superficial disruption. Disturbing
A "running parameter regime' is a combination of running can also breakup or blow apart conglomerations of particles.
parameters, including at least one of a fluid pump rate and To illustrate preferred embodiments, assume 1,000 feet of
a POOH rate, either of which may be fixed or variable. casing having the lower 300 feet filled with water and sand.
A wiper trip for coiled tubing indicates one movement of Assume this 1,000 feet of casing is in a well at a 45
the tubing into the borehole (RIH) and one sweeping back, inclination. Fill is usually Sand or Sandstone rock, crushed.
or pulling out, of the tubing from the borehole (POOH) (or It may typically include produced powder or proppant.
at least a significant segment of the borehole). One wiper trip 1O According to preferred embodiments of the invention, coiled
is traditionally used in the industry to refer to one RIH and tubing with a Selected dual nozzle will run down to and
one POOH. Typically, the running in hole and pulling out of through the upper 700 feet of casing while circulating a
hole is a complete run, from the surface to the end of the well pre-Selected cleanout fluid. Upon entering the fill a cleanout
and back. Effectively, it should be appreciated, a “wiper trip” fluid pump rate will be Selected, preferably from a pre
need only be through a Significant portion of the wellbore 15 modeling of the well and equipment parameters, Such that
containing the fill. POOH refers to pulling out of hole. The one or more power jets of the dual nozzle, preferably high
hole referred to is at least a significant Segment of the energy jets directed downhole, disturb and redistribute the
borehole, if not the full borehole. Typically POOH refers to fill and circulate Some fill out. A running in hole Speed will
pulling out of the borehole from the end to the surface. On be selected, preferably in conjunction with computer
Some occasions the relevant portion of the borehole does not modeling, Such that the run-in speed combined with the
include portions running all the way to the end. Selection of cleanout fluid or fluids, pump rate and the power
Substantially cleaning a borehole means removing at least jetting disturbs and redistributes substantially all of the fill
80% of the fill or particulate matter from the borehole. Such that the casing is no longer completely filled with the
Substantial fill indicates fill of such magnitude, given well fill. Running in hole while disturbing and redistributing fill
parameters, that a portion of the well is Substantially 25 in a deviated well in most cases will create equilibrium beds
occluded by particulate matter. The word fill is used to of fill out of the 100% packed fill. While 100% packed fill
include various types of fill that accumulate in the bottom or completely filled the interior of the bottom 300 feet of the
bottom portions of oil and gas boreholes. Typically, fill casing originally, the resulting (likely equilibrium) beds of
comprises Sand. The two words are Sometimes used inter fill after RIH do not completely fill the interior of the casing.
changeably. Fill might include proppant, weighting
materials, gun debris, accumulated powder or crushed Sand Upon reaching a target depth, the coiled tubing and nozzle
Stone. Fill might include general formation debris and well will be pulled out of the hole. Preferably now the direction
rock of the jetting nozzle will be Switched to a low energy uphole
An uphole directed jet directs fluid uphole. A forward or directed jet or jets. The controlled speed of pulling out of the
downhole directed jet directs fluid downhole. Pointing 35
hole, preferably determined by pre-modeling, is Selected in
downhole indicates that the exiting fluid is directed, or at conjunction with cleanout fluid, type of fill, location depth of
least has a Significant component of motion directed, in the fill, pump rate and other well parameters and equipment
downhole direction. Pointing uphole indicates that the exit parameters to wash the fill bed out of the hole. Equilibrium
ing fluid is directed, or at least has a significant component beds, if or to the extent not previously established, should
of motion directed, in the uphole direction. A coiled tubing 40
form uphole of the cleanout jet during pull out.
assembly refers to the coiled tubing and nozzle(s) and/or Pumps associated with pumping fluid in coiled tubing
other equipment attached to the coil downhole. A "high have a maximum practical Surface operating pressure. Tak
energy jetting action” means a nozzle jet with a Substantial ing the practical: operating preSSures associated with run
preSSure drop, in the order of at least 1000 psi, across the ning coiled tubing into account, the instant invention pref
nozzle orifice. A low energy jetting action means a nozzle jet 45 erably uses a high-pressure drop nozzle directing cleanout
with a Small pressure drop, in the order of 200 psi or less, fluid jets downhole during running in hole. Preferably while
acroSS the nozzle orifice. The values for "Substantial pres pulling out of hole the instant invention utilizes a low
Sure drop' required to define "high energy jetting as distinct preSSure drop nozzle with a jet or jets directed uphole.
from “low energy jetting” are a kinetic energy consideration. In general, the faster the pump rate of the cleanout fluid
The most preferred values are 1000 psi and above for high 50 and the faster the POOH rate the faster the total trip and the
energy and 50 psi and below for low energy. These figures less the total cost. There are limits to the rates, however, in
imply at least 200-400 ft/sec velocities for 1000 psi depend order to Substantially clean in one trip.
ing on the efficiency of the nozzle, and less than 100 ft/sec One aspect of the instant invention is disturbing particu
for the low energy regime. If it is assumed that the pump rate late solids while RIH with a coiled tubing assembly circu
stays essentially the same, then a high energy jetting action 55 lating at least one cleanout fluid through a nozzle having a
jet will have a Small orifice, relatively Speaking, while a low jetting action directed downhole. The method includes cre
energy jetting action jet will have a larger orifice, relatively ating particulate entrainment when pulling out of hole while
Speaking. circulating at least one cleanout fluid through a nozzle
When methods for cleaning substantial fill from a bore having a jetting action directed uphole. Further, the inven
hole in one wiper trip are discussed, it should be understood 60 tion includes pulling out of hole at Such a rate that Substan
that Such methods are capable, in at least the large majority tially all solids of the fill are maintained uphole at the end of
of cases, of Substantially cleaning fill from a borehole in one the coiled tubing assembly during pulling out of hole. It can
wiper trip. One wiper trip represents the ideal job, the "cusp be seen that if the coiled tubing assembly effectively main
of an efficiency curve by design. In practice, one wiper trip tains Substantially all of the particulate Solids uphole at the
is not a necessity. For instance, a “shuffle” (RIH/Partial 65 end of the assembly, then when the assembly has been pulled
POOH/RIH/full POOH) might be practiced. The partial out of the hole, Substantially all of the particulate solids will
POOH might only be a few feet. have been removed from the hole.
US 6,607,607 B2
7 8
Given well parameters and equipment parameters and a further sand can be deposited because the velocity of the
pump rate, Selected through engineering in order to enable fluid Stream with the entrained fluidized as Sand is too great.
a cleanout in one wiper trip, effecting a cost effective and The rate of pulling out of the hole should be sufficiently slow
Substantially complete cleanout in one wiper trip requires Such that the rearward facing jets can completely erode the
careful attention to the rate of pulling out of hole. It is leading edge of the equilibrium Sand beds as they move.
important to pull out of hole as quickly as possible as long Using coiled tubing modeling and job planning Software,
as all particulate Solids are maintained up hole of an end of it is possible to take Virtually every operational variable into
the coiled tubing assembly, for cost effectiveness reasons. account. Cleanouts in accordance with the instant invention
However, in order to effect the cleanout in one wiper trip, the can be designed to:
pulling out of hole rate must pay attention to the establish 1O Maximize debris removal
ment of equilibrium beds uphole of the end of the coiled Minimize nitrogen consumption
tubing. An equilibrium bed is a fill bed of such cross Reduce overall cost of cleanouts
Sectional dimension that the remaining annulus in the casing Fluid Selection and running procedures can be determined
(or hole or pipe) for circulating a cleanout fluid and in accordance with the instant invention according to
entrained particulates is Sufficiently Small that the Velocity 15 completion geometries and the type and Volume of fill to be
through that reduced annulus portion is Sufficiently high that removed. Fluid Selecting can be critical. Low-cost fluids
the entrained transport particulates can not Settle out, but are often cannot Suspend fill particles efficiently under down
transported uphole. hole conditions because these polymers will typically thin
In most cleanouts, equilibrium beds would be formed under high temperature and shear forces. Conversely,
behind the coiled tubing as the coiled tubing and nozzle are advanced fluids can be uneconomical to use, and even
run into the hole. That is, the downhole directed jet of the unnecessary if running procedures Such as varying the pump
nozzle will disturb the exiting fill. This disturbing will rate can lift the fill. The instant invention focuses on the most
redistribute the fill while at the same time circulate Some fill effective and economical approach, minimizing costs.
back out of the hole. In many situations, much of the If an owner/operator has a deviated well, compacted fill,
redistributed fill will form “equilibrium beds' behind the 25 a slim-hole completion, elevated bottom hole temperature
end of the coiled tubing nozzle while running in hole. By (BHT) or any of dozens of other complicating factors, the
definition of equilibrium beds, the velocity of the cleanout engineered approach to CT cleanouts of the instant invention
fluid and entrained Sand through the remaining part of the can produce the most cost-effective results.
annulus is Sufficiently high that no further fill particulates A well may not be clean just because it is flowing and the
can Settle out. Since an equilibrium bed, by definition, CT has reached target depth (TD). Fill can be fluidized by
cannot grow, the remaining Sand particulates or fill will be the CT, yet not lifted to the surface, but instead falling back
transported out of the hole. down into the rat hole when circulation stops. FIGS. 1-3
Pulling out of hole picks up the leading or downhole edge illustrate the problems that can occur with conventional CT
of the equilibrium bed, disturbs and entrains the leading cleanouts. FIG. 1 illustrates a 35 deviated well W sanded up
edge, and Sends the fill up the hole past the equilibrium beds 35 S to block or partially cover the perforations P. Wells that
to the Surface. Since the uphole bed has reached equilibrium produce sand S will usually fill the rathole RH slowly over
State, the entrained Sand particulates at the leading or down time. When the sand S starts to cover the perforations P, well
hole end of the equilibrium beds must be transported to the performance will be degraded.
Surface. The rate of pulling out of hole should not exceed a FIG. 2 illustrates the same well W with coiled tubing CT
rate Such that the above conditions can not be maintained. 40 run to TD and sand S fluidized above a stationary bed SB on
FIGS. 21A and 21B illustrate the above principles. FIG. the low side. If the critical velocity is not achieved, much of
21A illustrates coiled tubing CT. FIG. 21A illustrates an the sand S forms a sand bed SB on the low side LS of the
inclined wellbore DW filled at its bottom with original sand liner LN and is never produced to Surface. The well appears
F. Coiled tubing CT carrying coiled tubing assembly CTA is clean because the returns are clean and the coil is Stationary
run in the hole defined by inclined wellbore DW. Coiled 45 at TD.
tubing assembly CTA includes a nozzle N, such as with FIG. 3 illustrates the coiled tubing CT now removed and
forward facing jets FF.J. Forward facing jets have a jetting where the Sandbed SB has fallen down to the bottom and is
action directed downhole. Preferably forward facing jets occupying the rathole RH. Continuing Sand production will
have a high-pressure drop or high energy jetting action while fill the remaining rat hole sooner than if it had been fully
running in hole. Nozzle N with jets FFJ create fluid sand 50 cleaned. Cleaning the entire rat hole means leSS frequent
particulates FSP out of the original sand or fill F. The fluid cleanouts and more consistent wireline accessibility.
sand particulates move in fluid stream FS uphole toward the Cleaning a vertical well VW, FIG. 4, is often viewed as
Surface. Some Sand particulates SS Settle under gravity until Simple, yet there are many ways the cleanout can be made
they form equilibrium sand beds SB in the remaining faster and more efficient. A common factor limiting the rate
annulus area Auntil the annulus area for the fluid stream FS 55 at which a well can be cleaned is “annular choking in the
becomes sufficiently small by virtue of equilibrium sand production tubing PT. A conventional well has production
beds ESB that no further sand particulates can settle. That is, tubing PT that is much Smaller than the production casing or
the velocity of the fluid stream FS becomes so great in the liner LN. Achieving enough velocity in the liner to lift the
annulus that Sand particulates no longer Settle. Equilibrium fill in a reasonable period of time can result in Very high
sandbeds do not grow. During pulling out of hole or POOH, 60 Velocities in the production tubing. The high Velocities result
the cleanout fluid is jetted through rearward facing jets RFJ. in large friction preSSures that can overburden the well,
Preferably rearward facing jets are low pressure drop or low causing potentially damaging lost returns to the formation.
energy jets. Rearward facing jets pick up the leading edge This effect can be countered by using coiled tubing that is
LE of the equilibrium Sandbeds laid behind during running not too large, to provide for an adequate annular space, and
in the hole. This fluidized sand comprises fluidized excess 65 by choosing a fluid that has efficient lift properties in the
sand FES and moves in fluid stream FS uphole to the liner yet low friction pressure in the production tubing.
surface. Equilibrium sand beds ESB are of Such size that no Friction reducers in water (005 -0.1% loading) typically
US 6,607,607 B2
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offer the best fluid Selection when cleaning fine particles the effective narrowing of the annulous raises the Velocity of
(e.g., formation sand) from wells in the balanced or under the fluid Significantly. In this manner an equilibrium bed size
balanced State. These products reduce the friction pressure in can be reached wherein the fluid Velocity becomes So high
the coil, either permitting faster circulation rates or the use that particles no longer Settle.
of Smaller coil. Smaller coil can mean cheaper operations, FIG. 7 illustrates that in a 2%" completion, the volume of
can Solve offshore weight restriction problems, and also sand S that can be left partially filling the annulus A formed
reduce annular chocking. Friction reducers also reduce the by 1/4" tubing T resting in a 5,000 ft long deviated section
friction in the annulus, therefore, reducing the chocking of a well W can easily fill 100 ft of 7 casing.
effect. Cleanout rates can generally be increased by up to Many factors affect solids transport. One of these is the
50% using friction reducers as they typically permit higher cleanout fluid. High performance biopolymers as cleanout
fill penetration rates and quicker “bottoms-up' times. fluids can have benefits in deviated wells. These polymers
Finally, friction reducers slightly reduce the particle Settling rely on high gel Strength at low Shear rates to achieve fill
rate, aiding transportation in the well but at the same time Suspension and, under laminar flow conditions, have the
keep Surface Separation simple, not preventing Sand from ability to carry fill long distances along inclined wellbores
Settling in Surface tanks. The engineered approach of the 15 without depositing Significant amounts of fill on the low
instant invention can evaluate these complex factors and, by side. However, at high shear rates these fluids “thin' con
computer modeling, Suggest the cost effective Solution. siderably and, while shear thinning may help in keeping
Large particles often have Settling rates in water or friction pressures down, particle Suspension capability is
friction-reduced water that compare with the annular veloc Significantly reduced. The best combination of fluid prop
ity that can be achieved (e.g., 8 mesh Sand falls at about erties and shear rate for cleaning a casing or liner may be
8"/sec through water). Stiffer gels or foam are typically unsuitable for Smaller diameter production tubing. And as
required to limit the fall rate of large particles. Cleaning discussed above, leaving a shallow layer of fill in a deviated
Vertical wells in the overbalanced condition typically completion can result in a large Volume of Sand being left
requires a fluid that has Some leak-off control or blocking throughout the entire wellbore, thus impeding future access
properties. A Stiffer gel or foam is often used to control 25 into the well, reducing well production or requiring a repeat
leak-off. Producing the well during the cleanout can help cleanout operation earlier than necessary. A further compli
keep a well under balanced and minimize nitrogen consump cation to be taken into account is that under eccentric
tion. However, the well production does nothing to help annular flow conditions a significant quantity of the fill is
clean the rat hole beneath the perforations and results in transported much more slowly than the bulk speed of the
additional flow up the production tubing, So causing addi fluid. Computation of particle Slip thus can be crucial to
tional friction preSSure. Again the engineered Solution of the ensure that Sufficient hole Volumes are pumped and that
instant invention based on computer modeling can take Such operations are not halted prematurely while particles are still
factors into account and recommend the cost effective in transit to the Surface.
Solution. AS a further consideration, Viscous fluids are not well
As illustrated by the chart of FIG. 5, cleaning 420 micron 35 Suited to picking up fill from a bed that has formed. In
(40 mesh) sand out of a 7" liner requires over 70 minutes to horizontal wells in particular, the Sand bed must be physi
move fill 1,000 ft up the wellbore when pumping water at 1 cally disturbed to re-entrain the particles into the flow
bbl/min. Using friction reducers and maintaining the same Stream. This is often best achieved according to the present
flow rate reduces this time by 15 minutes. Taking advantage invention by using Special purpose reverse circulating
of the lower friction pressures by pumping faster reduces the 40 nozzles and an engineered Sweep of the Section by pulling
total time by another 30 minutes. Increasing the gel loading the coil up while circulating. The Speed of the Sweep is
to higher levels often creates more delays and leads to calculated based on the sand bed height and the fluid
complications with high pump preSSures, annular choking properties and rate.
and Surface Separation problems. Thus cleanouts using well Low Viscosity fluids circulated at high Velocities can be
assist require careful engineering to ensure that: 45 very effective in cleaning long horizontal Sections, espe
The lift velocities are sufficient beneath the perforations, cially where the best polymers are struggling to transport the
The friction preSSures are not too high in the completion, fill without forming large Sand beds. Only a high Velocity,
and low Viscosity fluid (Such as friction-reduced water) can
The Velocities are not too high in the completion or generate enough turbulence to pick up the fill particles once
Surface pipework, causing erosion. 50 they have settled. Friction-reduced water has the additional
The instant invention helps minimize all these potential advantages of being much cheaper than biopolymers and
problems through detailed engineering design and modeling. does not complicate the Surface handling of the returns.
Deviated and horizontal wells typically present a much Nitrogen is often added to the water to reduce the hydrostatic
greater challenge than vertical Wells. Further, the presence of head of the fluid and also increase the Velocities.
the coiled tubing on the low side of the wellbore disrupts the 55 The optimum System for cleaning deviated and horizontal
fluid Velocity profile, causing a Stagnant area where gravi Wells is very dependent on the exact well parameters.
tational forces dominate and Settling can occur. Thus, it is Particularly, extended reach Wells can require very high
not Sufficient to Simply ensure that the fluid velocity exceeds circulation rates and large Volumes of fluid to cleanout.
the fall rate of the particulates. FIG. 6 illustrates that, Incorrect job design can result in the cleanout taking days
transporting a particle PT 300 ft along a deviated hole DW 60 longer than necessary or in only a Small percentage of the fill
with a fluid moving at a uniform rate, Say 6"/Sec, requires the being removed. Generally, the techniques and approaches of
fluid to Suspend the particle for a significant time period. If the instant invention, including back Sweeping the fill using
the particle only has to settle 3" to hit the low side of the custom designed circulating nozzles and possibly including
well, the settling rate has to be as low as 0.005 inches/sec. the Slugging of different fluids and/or the intermittently
Many fluid velocity profiles are not uniform and thus 65 pumping at high rates with the coil Stationary to bypass coil
particle Suspension must be significantly higher than this fatigue constraints, can greatly reduce the cost and increase
Simple example predicts. However, as Settled beds build up, the effectiveness of deviated and horizontal well cleanouts.
US 6,607,607 B2
11 12
The table of FIG. 9 illustrates typical cleanout fluids, their The instant invention may include one of an array of
advantages, disadvantages and applications. Optimizing any Specialized tools to enhance cleanout operations, including
coiled tubing cleanout job requires careful fluid Selection. in particular high efficiency jetting nozzles. For instance,
The fluid must not be only the most appropriate to the preferred embodiments could have a Vortex nozzle Secured
cleanout technique chosen but it must also have the neces onto the end of a dual Switching nozzle to induce Swirling
Sary performance under downhole conditions. For example: into jetting. Proper tools help the instant invention Solve
Polymer gels generally thin at higher temperatures and cleanout problems in the most cost-effective manner, in
higher Shear rates. The gel properties downhole must be general.
understood. In Some instances fill will be compacted. In this situation,
Foaming agents are affected by downhole temperature a simple wash nozzle may not have enough jetting power to
and downhole fluids. The foaming agent must be com break up fill. The fill cannot be lifted out of the well until it
patible with all the fluids that might be present in the is first broken apart. The instant invention has developed a
wellbore. high velocity/high efficiency-jetting nozzle, FIG. 10A
The particulate fall rate as measured in a fluid can vary referred to herein as the Tornado tool. This tool provides
greatly depending on the particle size, shape and density, and 15 high-energy jets with greater destructive power than con
the density and Viscosity of the fluid. Bigger particles fall ventional wash nozzles. This tool is specifically designed by
faster than Smaller particles and even slightly Viscous fluids BJ Services Company, Houston, TeX., for cleanout opera
greatly hinder particle Settling. In Some cases, cleanouts may
lift the Small particles out of the well, leaving the larger ones tions. The tool has both forward and rearward facing jets.
behind. The table of FIG. 8 illustrates particle fall rates. The jetting fluid is diverted either predominately forward or
Computer modeling in accordance with the instant predominately backward, depending upon whether the tool
invention, including Simulation and analysis, represents an is jetting down into compacted fill or being used to "Sweep'
accurate and powerful design tool available for coiled tubing fill up the well on the low side of a wellbore. Engineering
cleanouts. Understanding the requirements for cleanouts algorithms calculate how fast the coil can be run into the fill
may be all for naught if the friction pressures, flow rates and and how fast the coil can be “swept' back up the well in
well production performance cannot be modeled accurately. 25 conjunction with the tool. Running in too fast could result in
In accordance with the instant invention modeling can too large a Sandbed being deposited behind the tool; pulling
accurately predict the flow regimes, Velocities and friction up too fast could result in fill being bypassed and left behind
preSSures at all points along the wellbore and down the as the tool is pulled back to Surface.
coiled tubing. The system preferably models the forces and The technology of the instant invention can greatly reduce
Stresses of the coiled tubing to ensure that the coil limitations the time required for the more challenging cleanouts and
are not exceeded, either by pressure or by bucking forces provide protection against coil becoming Stuck in the well
experienced in high angle wells. Real time analysis using due to Sand compacting behind the jetting nozzles.
computer modeling at the well site allows engineers to The instant invention further contemplates in Some
quickly recognize changing or unforeseen conditions in the embodiments using a downhole Separator to split a mixture
well, such as changes in bottom hole pressure (BHP) or well 35 of gas and liquid, Sending the gas to the annulus to lighten
productivity. The job design can then be immediately altered the column and Sending the liquid to the tool below. Com
to reflect the new design, ensuring continuing Safe and pressible fluids often do not make good jetting fluids, as the
efficient operations. Real-time data allows operators to jet does not remain coherent. The expanding gas, in effect,
match or update original job predictions. Preferably the blows apart the streaming fluid. The use of a downhole
modeling of the instant invention incorporates two-phase 40 Separator above a Vortex nozzle allows powerful liquid jets
flow within force...analyses, predicts time-to-failure when to be utilized even though co-mingled fluids are pumped
hitting obstructions, uses BHP, Surface preSSure and two through the coil.
phase flow to make accurate predictions, offers highly FIGS. 10A-10G illustrate preferred embodiments of
Stable, rapid computation for reliable performance and is nozzles, including a Tornado tool, as used with the instant
user-friendly and easy to run in the field. 45 invention. FIGS. 10A-10D illustrate one embodiment of a
Effectively reducing the TCO (total cost of operations) dual nozzle N, the Tornado tool. The nozzle includes for
attributable to CT well cleanouts requires a long-term per ward facing jets FFJ and rearward facing jets RFJ. It may be
Spective on the issue. AS discussed above, spending less on Seen that the forward facing jets have a Smaller orifice as
each job but performing more cleanout jobs can, over time, compared to the rearward facing jets. Thus, forward facing
be the most costly route. It is important to define the 50 jets FFJ are designed in the embodiments of FIG. 10 to
operational variables and understand the Significant cost provide a high-pressure drop, or to compromise high energy
drivers for each situation. Computer modeling analysis in jets. Rearward facing jets are dimensioned with larger
accordance with the instant invention yields comprehensive orifices to provide low energy, or to compromise low
CT job plans to help reach goals. The instant invention, in preSSure jets.
preferred embodiments, offers: 55 FIG. 10A illustrates the Tornado nozzle N with flow
Accurate, thorough CT job designs mandrel FM in its uphole Spring biased position. In Such
Real-time, on-site job monitoring position fluid F flows through the nozzle and mandrel FM
More complete debris removal and out forward facing jets FFJ. Rearward facing jets RFJ
Optimized fluid design are occluded by portions of flow mandrel FM in the flow
60 mandrel's Spring biased most uphole position. Spring SP
Optimized equipment Selection biases flow mandrel FM in its uphole or rearward position.
Optimized nitrogen consumption When flow through nozzle N is increased to a predesigned
Longer intervals of obstruction-free production amount, pressure on annular piston shoulder FMP of the
Reduced total cost of operation. flow mandrel, given the pressure drop through flow mandrel
The instant invention offers a complete package-an engi 65 FM, overcomes the biasing force of spring SP and flow
neered approach to coiled tubing cleanouts for maximum mandrel FM moves to the right in the drawing, to its forward
operational Success. or downhole position. As flow mandrel FM moves down
US 6,607,607 B2
13 14
stream the forward or downstream end of the flow mandrel Solids out of the wellbore, a proper wiper trip speed should
relatively tightly receives plug PG. Avery Small gap may be be selected based on operational conditions. There is no
designed between the inner diameter of lower end of flow previously published information related to the selection of
mandrel FM and plug PG, such that perhaps 1% of the fluid the wiper trip Speed. In this study, numerous laboratory tests
may continue to dribble through flow mandrel FM and reach were conducted to investigate wiper trip hole cleaning and
the forward facing jets. However, the bulk of the fluid in how hole cleaning efficiency is influenced by Solids trans
flow mandrel FM, when the flow mandrel has moved to its port parameters Such as; a) nozzle type, b) particle size, c)
forward or downstream position against Spring SP, now fluid type, d) deviation angle, e) multi-phase flow effect. The
flows through ports PT and out rearward facing jets RFJ. results indicate the following:
FIG. 10B illustrates the forward or downstream end of 1. Compared with Stationary circulation hole cleaning, the
nozzle N in larger detail. FIG. 10C illustrates the upstream use of the wiper trip produces a more efficient cleanout.
or rearward end of nozzle N in larger detail. As flow mandrel 2. For a given operational condition, there is an optimum
FM moves to the right in the drawings, or moves forward or wiper trip Speed at which the Solids can be completely
downstream, pins PN ride in J slots JS on the outer surface removed in the fastest period of time.
of flow mandrel FM. FIG. 10D offers an illustration of J slots 15 3. NoZZles with a correctly Selected jet arrangement yield
JS in greater detail. From FIG. 10D it can be seen that as a higher optimum wiper trip speed and provide a more
flow mandrel FM moves forward, pins PN slide in J slot JS efficient cleanout.
from an initial upmost position 10 to a maximum increased 4. The hole cleaning efficiency is dependent on the
flow rate position 20. When pressure is then decreased, pins deviation angle, fluid type, particle size, and nozzle
PN move in J slots JS to position 30, which is a lowermost type.
position for rearward jetting. It can be appreciated that if Correlation's have been developed that predict optimum
preSSure is again increased, pins PN can continue to traverse wiper trip speeds and the quantity of Solids removed from
J slots JS Such that flow mandrel FM can be returned to its and remaining in a wellbore for given operating conditions.
original upmost position for forward jetting. In that position The wiper trip provides an advantage for hole cleaning and
pins PN would again return to a position analogous to 25 can be modeled to provide more efficient operations.
indicated position 10 in J slot JS. Solids transport and wellbore cleanouts can be very
In general, to operate the preferred embodiment of FIGS. effective using coiled tubing techniques if one has the
10A-10D, the Tornado nozzle tool would be run in hole with knowledge and understanding of how the various parameters
the flow mandrel in the uppermost position. Such position interact with one another. Poor transport can have a negative
would allow forward jetting wash nozzles to be exposed. effect on the wellbore, which may cause Sand bridging and
Running in hole, thus, would include Washing and/or jetting as a result getting the coiled tubing Stuck. Coiled tubing then
the hole through the forward jetting wash nozzles. At target can be a very cost-effective technology when the overall
depth, the Tornado nozzle tool could be Switched to close the process is well designed and executed. The proliferation of
forward nozzles and expose the rearward nozzles. Switching highly deviated/horizontal wells has placed a premium on
is achieved by increasing the flow rate, and therefore the 35 having a reliable body of knowledge about Solids transport
preSSure drop, through the flow mandrel. This increase in in Single and multi-phase conditions.
preSSure drop creates a downward force on the flow mandrel In our previous studies, (Li, J. and S. Walker: “Sensitivity
to overcome the Spring force. AJ Slot in the flow mandrel Analysis of Hole Cleaning Parameters in Directional Wells”,
then controls the final position of the flow mandrel, once the paper. SPE 54498 presented at the 1999 SPE/ICoTa Coiled
preSSure drop is reduced by decreasing the flow rate. The 40 Tubing Roundtable held in Houston, Tex., May, 25-26,
flow mandrel, thus, typically resides in a rearward position 1999; Walker, S. and J. Li: “Effects of Particle Size, Fluid
with pins PN engaging J Slot JS at approximate position 10, Rheology, and Pipe Eccentricity on Cuttings Transport',
or in a forward position with pins PN engaging J slot JS in paper. SPE 60755 presented at the 2000 SPEICoTa Coiled
a more rearward position 30. Therefore, by increasing and Tubing Roundtable held in Houston, Tex., Apr. 5-6, 2000)
then decreasing the flow rate the tool can be cycled between 45 a comprehensive experimental test of Solids transport for
a forward jetting and a rearward jetting position. Stationary circulation was conducted. The Studies included
FIGS. 10E and 10F illustrate a second simpler embodi the effect of liquid/gas volume flow rate ratio, ROP, devia
ment of a jetting nozzle. FIG. 10E illustrates the nozzle with tion angle, circulation fluid properties, particle size, fluid
piston PN locked by shear pins SP in a rearward or uphole rheology, and pipe eccentricity on Solids transport. Said
position blocking rearward jetting nozzles RFJ. Fluid flow 50 papers are herein incorporated by reference and familiarity
ing through this nozzle exits forward jetting nozzles FFJ, as with those Studies is presumed. Based on the test results the
illustrated in FIG. 10E. When ball BL is sent down the data was therein analyzed, correlations were developed, and
tubing and into the nozzle, ball BL seats upon piston PN a computer program was developed.
shearing shear pins SP and sending piston PN with ball. BL In this Study, Simulated wiper trip hole cleaning effec
to seat upon the end of nozzle N. In such position fluid is 55 tiveness was investigated with various Solids transport
blocked to forward facing jets FFJ and exits rearward facing parameterS Such as deviation angle, fluid type, particle size,
jets RFJ. and nozzle type. Based on these test results, an existing
FIG. 10G illustrates a simpler work nozzle providing for computer program was modified and adjusted to include
no switching. All fluid flowing through nozzle N in FIG. these additional important parameters and their effect on
10G will exit both rearward facing jets RFJ and forward 60 wiper trip hole cleaning.
facing jets FFJ at all times. The flow loop shown in FIG. 11 was used for this project.
EXAMPLE
It was developed in the previous Studies, referenced above.
The flow loop has been designed to simulate a wellbore in
Wiper trips are a conventional field practice to clean a full scale. This flow loop consists of a 20ft long transparent
hole of Sand in cleanout operations. A wiper trip can be 65 lexan pipe with a 5-inch inner diameter to Simulate the open
defined as the movement of the end of coiled tubing in and hole and a 1/2" inch Steel inner pipe to Simulate coiled
out of the hole, at least a certain distance. In order to clean tubing. The flowloop was modified and hydraulic rams were
US 6,607,607 B2
15 16
installed to enable movement of the tubing (see FIG. 12). is pulled out of the hole too fast, solids will be left behind.
The inner pipe can be positioned and moved in and out of the There are other variables, which can affect the hole cleaning
lexan to Simulate a wiper trip. The loop is mounted on a rigid effectiveness during wiper trip cleanouts. The effect of the
guide rail and can be inclined at any angle in the range of following variables are investigated in this study:
0°-90° from vertical. 1. Nozzle type
When the coiled tubing is in the test section, the meth 2. Particle size
odology encompasses circulating the Sand into the test
Section and building an initial Sand bed with an uniform 3. Fluid type
height croSS the whole test Section. Then the methodology 4. Deviation angle
includes pulling the coil out of the test Section with a preset 5. Multi-phase flow effect
Speed. Effect of nozzle type. In this study three different nozzle
The recorded parameters include flow rates, initial Sand types were investigated. For Simplicity the nozzles can be
bed height before the coiled tubing is pulled out of the hole referred to as Nozzle A, B, and C. Each of these three
(POOH), and final sand bed height after the coil tubing is nozzles had different jet configurations and size. The effec
POOH, fluid temperature, pressure drop across the test 15 tive wiper trip hole cleaning time was investigated for each
Section and wiper trip speed. The data collected from the nozzle type and the optimum wiper trip speed for a wide
instrumentation is recorded using a computer controlled data range of flow rates was determined. Previous rules of
acquisition program. (See references above for more thumb' assumed that the cleanout of a wellbore takes
information.) approximately two hole volumes for a vertical wellbore.
From these experimental Studies, it has been observed that
Results and Discussion these rules of thumb are inadequate.
In this study (see above references regarding particle FIG. 14 displays the number of hole-volumes required to
Size), over 600 tests have been conducted to date using three clean the hole using water in a horizontal Section of a well
different particle sizes over a range of liquid and gas rates for the three different nozzle types. There is a non-linear
and at angles of 65 and 90 from vertical. The way in which 25 relationship between the number of hole volumes and the
the wiper trip affects the various Solids transport parameters in-Situ liquid Velocity. For a given type of nozzle, the
number of hole-volumes needed is constant when the in-Situ
was investigated. The results and discussion focus on the liquid Velocity is high enough. However with a low in-Situ
Situation that involves wiper trip hole cleaning in which the liquid velocity, the number of hole-volumes increases dra
tubing is pulled out of the hole while circulating water, gel, matically with the decreasing of the pump rate. An important
and multiphase gas combinations. thing to note is that, in certain ranges, the hole will not be
The Study focused on the wiper trip situation of pulling Sufficiently cleaned out if the minimum in-Situ Velocity is not
the coiled tubing out of the hole. The critical velocity attained and this value may vary depending on the type of
correlation developed in a previous study (see above nozzle. It is essential to Select a proper nozzle configuration
references) can be used to predict the Solids transport for the 35 and wiper trip Speed to ensure an effective cleanout. The
coiled tubing run-in-hole (RIH). Solids transport parameters that are interacting with one
The wiper trip is an end effect. When the circulation fluids another (shown in FIGS. 13 and 14) can be correlated using
are pumped down through the coil and out of the end and a dimensionless wiper trip Speed parameter. From this
returned to Surface through the annulus, the flow changes information proper nozzles, flow rates, and wiper trip speed
direction around the end of the coil and the jet action only 40 can be Selected to provide an effective cleanout.
fluidizes the Solids near the end of the coil. When the flow Effect of particle size. The previous study results (see
conditions are less than the critical condition Solids will fall above references) indicate that there is a particle size that
out of Suspension for a highly deviated wellbore. poses the most difficulty to cleanout with water for the
Based on the experimental observation in this study, for a Stationary circulation mode, and from the Study it is of the
given Set of conditions, there is an optimum wiper trip speed 45 order of 0.76 mm diameter frac sand. In contrast to station
at or below which sands can be removed completely when ary circulation hole cleaning, the wiper trip hole cleaning
the coil is pulled out of the hole. When the coil tubing is Situation reveals different conclusions based on particle size.
POOH at a wiper trip speed higher than the optimum wiper In this Study three types of particles ranging in size were
trip Speed, there is Some Sand left behind. In general, more investigated: 1) wellbore fines, 2) frac sand, 3) drilled
Sand is left in the hole as the wiper trip Speed is increased. 50 cuttings. FIG. 15 displays the results of the investigation of
The hole cleaning efficiency is defined as the percentage of particle size that included a wide range, and the results
sand volume removed from the hole after the wiper trip Suggest that for the horizontal wellbore with a high pump
versus the initial sand volume before the wiper trip. 100% rate, larger particles have a higher hole cleaning efficiency
hole cleaning efficiency means that the hole was completely than Smaller particles do. The results for low pump rate were
cleaned. In general a higher pump rate results in a higher 55 the opposite.
optimum wiper trip speed. The vertical axis of FIG. 13 is The effect of particle size on solids transport is different
equal to 100% minus the hole cleaning efficiency. For, a between Stationary circulation and wiper trip hole cleaning.
given type of nozzle and deviation angle, there is a minimum Due to the complexity of the interaction between the various
flow rate at which the hole cleaning efficiency is near to Zero. Solids transport parameters it is a challenge to generalize and
For low pump rate, the remaining Sand Volume in the hole 60 draw conclusions. For more information on particle size
increases non-linearly with the dimensionless wiper trip effects please refer to the above references.
Speed. However, with high flow rate the remaining Sand Effect of fluid type. Wiper trip hole cleaning adds a new
Volume in the hole increases linearly with the dimensionless dimension with respect to fluid type. In contrast to Stationary
wiper trip Speed. FIG. 13 displays these three parameters circulation hole cleaning, where gel could not pick up the
that can be correlated and used to Select adequate flow rates 65 solids and only flowed over the top of the solids bed (see
and wiper trip speed to ensure an effective cleanout opera above references), for the highly deviated wellbore the wiper
tion. Again, if the pump rate is too low or the coiled tubing trip hole cleaning method transports the Solids effectively.
US 6,607,607 B2
17 18
Due to the turbulence created at the end of the coiled tubing Based on the experimental Study and the analysis of the
from the fluid, gels have the ability to pick up and entrain hole cleaning process, it was found that the use of the wiper
solids and transport them along the wellbore. For small trip produces a more effective cleanout than Stationary
particles like wellbore fines, the use of gel for long hori circulation hole cleaning. It was found that for a given Set of
Zontal Sections is beneficial. The larger particles Such as frac well conditions, there is an optimum wiper trip speed at
Sand or drilled cuttings, tend to fall out at a more rapid pace. which the Solids can be completely removed. The optimum
The effect of fluid type on the hole cleaning efficiency is wiper trip speed is dependent on the deviation angle, fluid
shown in FIG. 16. There is no significant difference between type, particle size, and nozzle type. Nozzles with correctly
Xanvis and HEC for all tested flow rates. There is no Selected jet arrangements yield an effective cleanout opera
difference between water and gel except for very low pump tion.
rates i.e. at very low Shear rates, when gels outperform The investigation of particle size included a wide range
water/brines. Therefore, in the case where the liquid in-Situ and the results Suggest that when the borehole is at various
Velocity is low, pumping gel would clean the hole better. inclined angles for particles from 0.15 mm up to 7 mm in
Effect of deviation angle. The experimental results in the
previous study (see above references) show that the highest diameter, there is a significant effect on Solids transport.
minimum in-situ liquid Velocity needed is approximately 15 Spherical particles Such as frac Sands are the easiest to
60. The effect of deviation angle on the hole cleaning cleanout and wellbore fines prove more difficult, but the
efficiency with the wiper trip mode is shown in FIG. 17. The larger particles Such as drilled cuttings pose the greatest
general trend at higher flow rates typical for 1/2" coiled difficulty for solids transport.
tubing is that there is not a significant difference in Solids Fluid rheology plays an important role for Solids
transport effectiveness between horizontal and 65 degrees. transport, and to achieve optimum results for hole cleaning,
There are distinct differences for fluid types, for example the best way to pick up solids is with a low viscosity fluid
with water, solids transport proves more difficult at 65 in turbulent flow, but to maximize the carrying capacity, a
degrees than at horizontal, but, with XanVisgel, 65 degrees gel or a multiphase System should be used to transport the
is easier, than horizontal. Solids out of the wellbore.
Multi-phase flow effect. Multi-phase flow is very complex 25 The large number of independent variables influencing
and if used incorrectly can be a disadvantage and provide Solids transport demands that a computer model be used to
poor hole cleaning, whereas if the addition of the gas phase make predictions effectively.
is understood, there are advantages that prove beneficial for The foregoing description of preferred embodiments of
solids transport. FIGS. 18 and 19 display the multi-phase the invention is presented for purposes of illustration and
flow effect for various gas volume fractions. With the description, and is not intended to be exhaustive or to limit
addition of the gas phase up to a gas Volume fraction (GVF) the invention to the precise form or embodiment disclosed.
of 50% in Stationary circulation, hole cleaning can be The description was Selected to best explain the principles of
improved by up to 50%. Whereas with wiper trip hole the invention and their practical application to enable others
cleaning, the addition of the gas phase up to GVF 50% only skilled in the art to best utilize the invention in various
produces an improved cleanout effectiveness of 10-20%. 35 embodiments. Various modifications as are best Suited to the
For example, if the well was 80% cleaned out with water in particular use are contemplated. It is intended that the Scope
the wiper trip hole cleaning mode, with the addition of the of the invention is not to be limited by the specification, but
gas phase the Solids transport effectiveness could be to be defined by the claims set forth below.
increased to 85%. Even though with stationary circulation What is claimed is:
hole cleaning there is a Substantial increase in hole cleaning 40 1. A method for cleaning fill from a borehole, comprising:
effectiveness with the addition of the gas phase, the use of disturbing particulate Solids of the fill while running in
the wiper trip method is more effective than just the addition hole (RIH) with a coiled tubing assembly circulating at
of the gas phase. The addition of the gas phase is beneficial least one cleanout fluid through a nozzle having a
in low pressure reservoirs and where there are limitations jetting action directed downhole;
due to hydroStatic conditions. 45
creating particle entrainment by pulling out of the hole
As shown in FIG. 18, there is not a significant effect on (POOH) while circulating at least one cleanout fluid
Solids transport effectiveness with the addition of the gas through a nozzle having a jetting action directed
phase at high relative in-situ liquid velocities. AS the relative uphole; and
in-Situ liquid Velocity is decreased to a low value, Solids controlling a pump rate of cleanout fluid and a coiled
transport effectiveness is dependent on the addition of the 50
tubing assembly POOH rate according to at least one of
gas phase. AS the gas phase is added the Solids transport a Selected pump rate regime and a Selected POOH rate
effectiveness decreases until more gas is added and the regime Such that Substantially all particulate Solids of
relative in-Situ Velocity Starts to increase, which causes an the fill are maintained uphole of an end of the coiled
improvement in Solids transport effectiveness. tubing assembly during POOH.
FIG. 19 displays the effect of adding gas to the system 55
2. A method for cleaning fill from a borehole in one wiper
resulting in a decrease in optimum wiper trip speed. The trip, comprising:
three curves represent Situations that involve the addition of jetting downhole, through a nozzle connected to coiled
gas and the reduction of the liquid flow rate, keeping the tubing, at least one cleanout fluid during at least a
total combined flow rate constant. There is a greater depen portion of RIH;
dency on the addition of gas at the higher total flow rates on 60
the optimum wiper trip Speed compared to the lower flow jetting uphole through a nozzle connected to the coiled
rates. AS more gas is added with a constant total combined tubing at least one cleanout fluid during at least a
flow rate the optimum wiper trip speed decreases, but the portion of POOH;
Solids transport effectiveness generally improves when gas pumping, during at least a portion of POOH, at least one
is added to the system with a fixed liquid flow rate as shown 65 cleanout fluid at a Selected pump rate regime;
in FIG. 18. The complexity of the multi-phase flow behavior POOH, for at least.a section of the borehole, at a selected
makes it more difficult to generalize the test results. POOH rate regime; and
US 6,607,607 B2
19 20
Substantially cleaning the borehole of fill. 22. The method of claim 10 or 11 that includes selecting
3. The method of claim 1 wherein controlling pump rate at least one of a pump rate regime and a POOH rate regime
includes controlling an in-situ liquid phase Velocity. during a running of the coiled tubing in the borehole.
4. The method of claim 1 wherein controlling pump rate 23. The method of claim 10 or 11 wherein the uphole
includes controlling the effect of gas-liquid Slip Velocity on directed jet includes a low energy jet.
in-Situ liquid phase Velocity and multi-phase flow. 24. The method of claims 1, 2 or 11 wherein a pump rate
5. The method of claim 1 that includes computer model regime is Selected at least in part based on computer mod
ing to determine a value for a limiting concentration of eling taking into account at least one well parameter and at
Solids in a Slurry for a Selection of cleanout fluid and a liquid least one equipment parameter.
in-Situ Velocity. 1O 25. The method claim 10 or 11 that includes jetting the
6. The method of claim 1 or 2 that includes high energy coiled tubing into fill in the borehole during RIH using at
jetting downhole. least one downhole directed jet connected to the coiled
7. The method of claim 1 or 2 that includes low energy tubing.
jetting uphole. 26. The method of claim 25 wherein the dowhhole
8. The method of claim 1 or 2 that includes reaching a 15
directed jet includes a high energy jet.
target depth with the coiled tubing between a RIH and a 27. The method of claim 1, 2, 10, or 11 wherein the
POOH. borehole includes at least a horizontal portion.
9. The method of claim 1 or 2 that includes Switching a 28. The method of claim 10 wherein the selecting at least
direction of cleanout fluid in a nozzle between a downhole one of pump rate regime and POOH rate regime takes into
account well parameters for the borehole and equipment
direction to an uphole direction. parameters for the cleaning.
10. A method for cleaning a borehole of fill, comprising: 29. The method of claim 28 or 15 wherein the well
Sweeping back at least one uphole directed jet connected parameters include well geometry and well pressure and
to coiled tubing while POOH at a selected POOH rate wherein the equipment parameters include coiled tubing
regime; diameter and type of cleaning fluid.
pumping at least one cleanout fluid at a Selected: pump 25 30. The method of claim 28 or 15 wherein the selecting at
rate regime down the coiled tubing and out the at least least one of pump rate regime and POOH rate regime takes
one uphole directed jet during at least a portion of into account friction pressure and shear rates within the
POOH; and borehole.
Selecting at least one of pump rate regime and POOH rate 31. The method of claim 28 or 15 wherein the selecting at
regime for Substantially cleaning the borehole of fill. least one of pump rate regime and POOH rate regime takes
11. The method of claim 10 that includes selecting, by into account liquid and gas flow and particle Slip.
computer modeling, at least one of pump rate regime and 32. The method of claims 1, 2, 10, or 11 wherein the at
POOH rate regime. least one cleaning fluid includes two phase fluid.
12. The method of claim 10 that includes selecting, by 33. The method of claim 1, 2, 10 wherein a POOH rate
computer modeling, at least one of pump rate regime and 35 regime is Selected at least in part based on computer mod
POOH rate regime such that one Sweep Substantially cleans eling taking into account least one well parameter and at
the borehole of fill. least one equipment parameter.
13. The method of claim 11 that includes selecting at least 34. The method of claim 1, 2, 10, or 11 wherein the
one of a pump rate regime and a POOH rate regime during borehole includes a deviated portion.
a running of the coiled tubing in the borehole. 40 35. A method for cleaning out a borehole of particulate
14. The method of claim 11 wherein the computer mod matter, comprising:
eling takes into account well parameters for the borehole and modeling a cleanout, taking into account a plurality of
equipment parameters for the cleaning. well parameters and a plurality of equipment
15. The method of claim 12 wherein the computer mod parameters, to produce at least one running parameter
eling takes into account friction pressure and shear rates 45 regime predicted to clean to a given degree of the
within the borehole. borehole with coiled tubing attached to at least one
16. The method of claim 10 further comprising the step of forward jet and one reverse jet; and
controlling a pump rate of cleanout fluid and a coiled tubing cleaning the borehole to attain the given degree of
assembly POOH rate according to at least one of a selected cleanout with the coiled tubing, implementing Said at
pump rate regime and a Selected POOH rate regime Such that 50 least one produced running parameter regime.
Substantially all particulate Solids of the fill are maintained 36. The method of claim 35 that includes selecting a
uphole of an end of the coiled tubing assembly during running parameter regime to minimize costs.
POOH. 37. The method claim 35 wherein the modeling includes
17. The method of claim 16 wherein the controlling pump pre-modeling and real-time modeling and wherein the clean
rate includes controlling an in-situ liquid phase Velocity. 55 ing includes Selecting a first combination of running param
18. The method of claim 10 or 11 that includes reaching eters produced from pre-modeling and Selecting a Subse
a target depth with the coiled tubing between a RIH trip and quent combination of running parameters produced for
a POOH trip. real-time modeling.
19. The method of claim 10 or 11 further comprising 38. The method of claim 35 that includes attaining Sub
performing a shuffle for Substantially cleaning fill from the 60 Stantially complete particulate removal in one wiper trip.
borehole. 39. A method for cleaning fill from a borehole, compris
20. The method of claim 10 of 11 that includes reaching Ing:
a target depth with the coiled tubing between a partial RIH modeling Solids transport in a deviated borehole while
trip and a partial POOH trip. POOH with coiled tubing according to a POOH rate
21. The method of claim 10 or 11 that includes selecting 65 regime and while jetting uphole at least one cleanout
a pump rate regime and a POOH rate regime prior to fluid according to a cleanout fluid pump rate regime to
Sweeping. clean fill from a borehole.
US 6,607,607 B2
21 22
40. The method of claim 39 including modeling two phase 46. The method of claim 39 in which the step of modeling
flow in the borehole. Solids transport in a deviated borehole further comprises
41. The method of claim 39 wherein the modeling com computer modeling for modeling Solids transport.
putes in-situ liquid phase Velocity. 47. A method for cleaning fill from a borehole, compris
42. The method of claim 39 wherein the modeling com 5 ing:
putes an effect of gas-liquid slip Velocity on in-situ liquid RIH through fill with CT while circulating at least one
phase Velocity in multi-phase flow. cleanout fluid through a downward directed jet;
43. The method of claim 39 wherein the modeling com
putes a value for a limiting concentration of Solids in a slurry POOH while jetting at least one cleanout fluid uphole
for a choice of cleanout fluid and fluid in-situ Velocity. Such that a downhole edge of a fill bed is entrained; and
44. The method of claim 39 wherein the modeling takes POOH at a rate such that an equilibrium bed is established
into account the rheology of the cleanout fluid and the uphole of the jet.
configuration of a jetting nozzle. 48. The method of claims 1, 2, 25 or 47 wherein RIH
45. The method of claim 39 wherein the modeling outputs includes running through a portion of Substantial fill.
a maximum value of a RIH speed and a POOH speed for 15
which all particulate matter will be circulated out of the well. k k k k k
UNITED STATES PATENT AND TRADEMARK OFFICE
CERTIFICATE OF CORRECTION
PATENT NO. : 6,607,607 B2 Page 1 of 1

APPLICATIONNO. : 09/799990
DATED : August 19, 2003
INVENTOR(S) : Scott A. Walker, Jeff Li and Graham Wilde
It is certified that error appears in the above-identified patent and that said Letters Patent is
hereby corrected as shown below:
Column 16, line 22, delete “14 and insert --15

Column 16, line 37, delete “13 and insert --14--
Column 16, line 50, delete “15” and insert --16--
Column 17, line 8, delete “16' and insert --17--
Column 17, line 18, delete “17 and insert --18--
Signed and Sealed this

Fourteenth Day of November, 2006
WDJ
JON. W. DUDAS
Director of the United States Patent and Trademark Office

United States Patent: (10) Patent No.: (45) Date of Patent

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USOO66O7607B2

(12) United States Patent (10) Patent No.: US 6,607,607 B2

(54) COILED TUBING WELLBORE CLEANOUT 5.984.011 A 11/1999 Misselbrook et al.

(21) Appl. No.: 09/799,990 OTHER PUBLICATIONS

NSN NaNYKZ \ K'idi

1N - SITU L/QUID VELOCITY --

F/G 17 C--O 327 LPM WATER A-A 204 LPM HEC

100 LPM WATER/ 100 PM WATER

PATENT NO. : 6,607,607 B2 Page 1 of 1

Column 16, line 22, delete “14 and insert --15

Signed and Sealed this

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