Industry Context

Scale is a significant issue in hydrocarbon wells across the UK Continental Shelf (UKCS) and beyond. This leads to compromised integrity and production, reduced efficiency and well shutdowns. Additionally, it can negatively impact P&A operations and carbon capture and storage (CCS) re-use potential.

Chemical squeezes, chemical washes and mechanical removal are the traditional methods for dealing with downhole scale. However, complexities within the wellbore architecture can provide constraints such as nipple profiles, making it challenging to reach scale surfaces.

Project Overview

The Pipetech Downhole Scale Remediation Tool (DSR) is a patent-approved jetting design and scale remediation system for the cleaning and reinstatement of hydrocarbon and CCS wells.

An industry first, DSR has the ability to track internal diameter changes downhole and clean effectively back to the bare metal with no damage to existing casing, tubulars or tools, negating the need for chemicals.

It incorporates a semi-flexible hose to remove scale, wax, cement and corrosion from the inner wellbore. It can clean areas other systems struggle to access, such as downhole safety valves and screens.

In addition, Pipetech’s DSR can support with decommissioning of wells during the plug and abandonment (P&A) by effectively cleaning to prepare a sound surface for setting bridging plugs.

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Key Results and Achievements

Engineering design conceptual development:

DSR had to utilise industry standard components, such as metallurgy and elastomers – and industry recognised methods relating to deployment, activation and drive of the tool. The design was specified to a maximum of 2.875” and all angles were assessed for “hang-up” potential.

Manufacture of DSR prototype:

Parts were tested, inspected and manufactured at the facility of Pipetech’s approved manufacturing partner.

DSR prototype testing:

Initial testing assessed the fundamentals of the tool such as pressure ratings and fit testing of components and sealing. Additional testing was then conducted where the tool underwent prototype testing in a pumped water flow loop at Pipetech’s Aberdeenshire facility. This included assessing the functionality of the tool:

• Flow through the tool
• Sleeve activation
• Rotation nozzle
• Nozzle tracking ID of casing
• Sleeve deactivation

Production tool design iteration & re-work:

During the prototype testing, it was determined that the turbine needed to produce higher torque to counteract any back pressure created once the DSR was under load with water pressure. This data led to an update in the design; the iterated design then successfully delivered anticipated flow-pressure-torque results in repeat flow-loop testing.

NZTC’s project successfully moved the technology from TRL 4 to TRL 7.  It has already secured carry-forward industry support to commence a live field pilot to achieve market readiness by mid/late 2025 to move the technology to TRL8.

The Pipetech team during the DSR trial at their Aberdeen testing facility – Click to expand

Industry Value

Pipetech’s Downhole Scale Remediation (DSR) has the potential to provide safety, environmental and cost/time benefits. Furthermore, the DSR service could offer opportunities in support of CCS through remediation of existing wellstock that may be suitable but are stranded due to scaling.

There is a significant need within the UKCS to provide an alternative method for descaling SSSVs and GLMs to reinstate wells, especially since some wells cannot be accessed using traditional methods. As well as providing commercial benefits within P&A along with CCUS, DSR can work in geothermal space to provide a well descaling solution that could help keep costs low.

NZTC’s Role and Support

NZTC provided funding to support design, manufacture and testing prototype DSR downhole assembly.

“Thanks to the support received from the Net Zero Technology Centre, we have had the backing to take a major step forward in the support we provide the industry. Since presenting the NZTC team with the initial concept for the DSR, they have demonstrated complete confidence and belief in what we are trying to achieve. Alongside the funding provided to make the DSR a reality, NZTC has provided advice and insight that has helped us to keep improving the DSR and its potential usages across the sector. We are proud to have been part of NZTC’s ‘Emissions Reduction’ programme and look forward to sharing the results of the DSR’s application once it is on the market. “

Leonard Hamill, Operations Director, Pipetech