MULTI-MODAL WELLBORE CLEANING SYSTEMS AND ASSOCIATED TOOLS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application claiming priority to U.S. provisional patent application No. 63/712,149 filed Oct. 25, 2024, and entitled “Multi-Modal Wellbore Cleaning Systems and Associated Tools,” which is hereby incorporated herein by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

Wellbore cleaning tools (sometimes also referred to as “cleanup tools”) are often utilized during the initial drilling or completion of wellbores extending through subsurface regions and which are ultimately utilized for producing hydrocarbons from the subsurface region. Particularly, well systems often include one or more wellbores extending through an earthen subsurface region. The operation of well systems generally proceeds in phases including a drilling phase in which the wellbore is initially drilled, a completion phase in which the wellbore is completed (e.g., fluid communication is selectably established between the subsurface region and the wellbore) in preparation for production, and a production phase in which hydrocarbons are produced from the completed wellbore. Generally, wellbore cleaning tools are designed to remove debris, residue, and obstructions from an inner surface of a tubular string that lines the wellbore typically referred to as a casing string or simply “casing.” The casing serves to stabilize the wellbore and protect it from collapse, but contaminants such as drilling mud, scale, cement, corrosion, and other foreign materials may accumulate along its inner surface during installation. If not properly removed or otherwise abated, these contaminants can interfere with subsequent operations, such as completion and/or production phases of a well system comprising the wellbore.

SUMMARY OF THE DISCLOSURE

An embodiment of a wellbore cleaning tool deployable into a wellbore extending through a subsurface region, the wellbore cleaning tool comprises an elongate tool body and comprising at least one annular groove positioned along the tool body and connectable to a tool string deployable into the wellbore, one or more tool connectors coupled to the annular groove of the tool body, and one or more engagement tools coupled to the tool body through the one or more tool connectors whereby an annular gap is formed entirely between the tool body and the one or more engagement tools, and wherein the one or more engagement tools are configured to clean an inner surface of a tubular member positioned in the wellbore. In some embodiments, the one or more tool connectors comprise a split sleeve. In some embodiments, the wellbore cleaning tool comprises one or more annular centralizers supported on the one or more tool connectors. In certain embodiments, the wellbore cleaning tool comprises a plurality of fasteners configured to couple the one or more centralizers to the one or more tool connectors. In certain embodiments, the one or more engagement tools comprise at least one of a blade tool, a brush tool, a basket tool, or a magnet tool. In some embodiments, the one or more engagement tools are slidably positioned over the tool body to releasably couple the one or more engagement tools to the tool body. In some embodiments, the wellbore cleaning tool comprises one or more annular bearings positioned at least partially in the groove of the tool body to permit relative rotation about a central axis of the wellbore cleaning tool between the tool body and the one or more engagement tools. In certain embodiments, the tool body and the one or more engagement tools are each positioned along a shared central axis of the wellbore cleaning tool. In certain embodiments, the wellbore cleaning tool comprises a plurality of the one or more engagement tools longitudinally spaced along the tool body whereby each of the plurality of the one or more engagement tools are entirely spaced from the tool body by the annular gap. In some embodiments, the wellbore cleaning tool comprises one or more annular central tool support members coupled longitudinally between the plurality of the one or more engagement tools for locating the plurality of the one or more engagement tools along a shared central axis. In some embodiments, an outer diameter of the one or more engagement tools defines a maximum outer diameter of the wellbore cleaning tool.

An embodiment of a wellbore cleaning tool deployable into a wellbore extending through a subsurface region comprises an elongate tool body and comprising an annular upper groove and an annular lower groove spaced along a longitudinal length of the body, a retainer assembly mounted on each of the upper groove and the lower groove of the tool body, wherein the retainer assembly comprises a sleeve and a one or more bearings coupled to the sleeve, a centralizer coupled to each of the retainer assembly, the centralizer comprising a first end and a longitudinally opposed second end, wherein the second end comprises an annular groove radially surrounding the second end, and one or more engagement tools coupled to the centralizer and configured to clean an inner surface of a tubular member positioned in the wellbore, wherein a portion of the one or more engagement tools is received in the annular groove, and wherein an annular gap is formed between the one or more engagement tools and the tool body permitting the centralizer and the one or more engagement tools to rotate independently of each other. In certain embodiments, the sleeve comprises a split sleeve. In certain embodiments, the wellbore cleaning tool comprises a plurality of fasteners configured to couple the centralizer to the retainer assembly. In some embodiments, the one or more engagement tools comprise at least one of a blade tool, a brush tool, a basket tool, or a magnet tool. In some embodiments, the wellbore cleaning tool comprises a wear ring and a central tool support member both coupled to the tool body. In certain embodiments, the wellbore cleaning tool comprises a plurality of the one or more engagement tools longitudinally spaced along the tool body whereby each of the plurality of the one or more engagement tools are entirely spaced from the tool body by the annular gap. In certain embodiments, an outer diameter of the one or more engagement tools defines a maximum outer diameter of the wellbore cleaning tool.

An embodiment of a method for providing a wellbore cleaning tool deployable into a wellbore extending through a subsurface region comprises (a) providing a tool body comprising an annular upper groove and an annular lower groove spaced along a longitudinal length of the body, (b) coupling one or more bearings to sleeves of a plurality of retainer assemblies, (c) mounting the plurality of retainer assemblies on the upper groove and the lower groove of the tool body, (d) coupling centralizers to the plurality of retainer assemblies, each centralizer comprising a first end and a longitudinally opposed second end, wherein the second end comprises an annular groove radially surrounding the second end, and wherein the annular groove is downhole from the first end, and (e) sliding an engagement tool over the centralizer, wherein a portion of the engagement tool is received in the annular groove and the engagement tool is configured to clean an inner surface of a tubular member positioned in the wellbore. In some embodiments, the engagement tool comprises at least one of a blade tool, a brush tool, a basket tool, or a magnet tool.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be obtained from the following detailed description with reference to the attached drawing figures as summarized below, in which:

FIG. 1 is a schematic view of a well system in accordance with principles disclosed herein;

FIG. 2 is a side cross-sectional view of an embodiment of a wellbore cleaning tool in accordance with principles disclosed herein;

FIG. 3A is a perspective view of another embodiment of a wellbore cleaning tool in accordance with principles disclosed herein;

FIG. 3B is an exploded view of the wellbore cleaning tool of FIG. 3A;

FIGS. 4A-4D are views of an exemplary method for assembling the wellbore cleaning tool of FIG. 3A in accordance with principles disclosed herein;

FIG. 5A is a perspective view of an embodiment of a tool connector in accordance with principles disclosed herein;

FIG. 5B is a perspective view of an embodiment of a bearing in accordance with principles disclosed herein;

FIG. 5C is a perspective view of an embodiment of a blade tool in accordance with principles disclosed herein;

FIG. 6A is a perspective view of another embodiment of a wellbore cleaning tool in accordance with principles disclosed herein;

FIG. 6B is a perspective view of an embodiment of a brush cage in accordance with principles disclosed herein;

FIG. 6C is a perspective view of an embodiment of a plurality of brush elements in accordance with principles disclosed herein;

FIG. 7A is a perspective view of another embodiment of a wellbore cleaning tool in accordance with principles disclosed herein;

FIG. 7B is an exploded view of the wellbore cleaning tool of FIG. 7A;

FIG. 8 is a view of another wellbore cleaning tool in accordance with principles disclosed herein; and

FIG. 9 is a flowchart of an embodiment of a method for providing a wellbore cleaning tool deployable into a wellbore extending through a subsurface region.

DETAILED DESCRIPTION

The following discussion is directed to various exemplary embodiments of the present disclosure. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment. Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. Any reference to up or down in the description and the claims is made for purposes of clarity, with “up”, “upper”, “upwardly”, “uphole”, or “upstream” meaning toward the surface of the borehole and with “down”, “lower”, “downwardly”, “downhole”, or “downstream” meaning toward the terminal end of the borehole, regardless of the borehole orientation. Further, the term “fluid,” as used herein, is intended to encompass both fluids and gasses.

As described above, wellbore cleaning tools are utilized in well systems for cleaning the inner surface of the tubular string lining the wellbore (e.g., the casing) in preparation for the subsequent completion and eventual production phases of the well system. Cleaning of the inner surface of the casing string provides a generally uniform inner surface or inner diameter (ID) which completion tools such as plugs, packers, and the like may effectively seal against during the completion phase as part of, for instance, a hydraulic fracturing operation and the like. Additionally, cleaning the inner surface of the casing maximizes the flow area through the casing string which may assist in maximizing production of hydrocarbons from the subsurface region during a production phase of the well system.

Wellbore cleaning tools may take different forms providing different functionalities for cleaning the wellbore. For instance, wellbore cleaning tools include or carry engagement tools such as, for example, scrapers, brushes, baskets, and magnets. Generally, scraper tools are equipped with hard-edged blades designed to physically scrape debris and solid buildup from the inner surface of the casing. Such wellbore scraper tools are typically used to remove cement sheaths, scale, and hard deposits that adhere to the inner surface of the casing during drilling and/or completion operations. Additionally, brush tools generally include brushes comprising flexible bristles or wires configured to remove softer residues or fine particles from the inner surface of the casing. For instance, brush tools may be used to dislodge mud cakes, rust, and other soft contaminants that may hinder well integrity or fluid flow through the casing string. In addition, basket tools typically capture larger debris and fragments that may fall to the bottom of the wellbore during wellbore cleaning operations. In this manner, basket tools may prevent such debris from clogging the wellbore or interfering with other downhole tools. Further, magnet tools are typically employed to capture ferrous debris, such as metal shavings and/or particles resulting from downhole tool wear or casing corrosion, which could otherwise contaminate the wellbore and damage downhole tools used in subsequent operations or otherwise interfere with their operability.

Wellbore cleaning tools such as, for example, scraper tools, brush tools, basket, and magnet tools described above, are typically deployed into and through the wellbore using a surface-deployed tubing string such as a drill string, a coiled tubing string, and the like along which a selected cleaning tool is positioned. In this manner, the position of the wellbore cleaning tool may be controlled at the surface via manipulating the tubing string to which the wellbore cleaning tool is coupled. Particularly, wellbore cleaning tools are typically moved along the length of the wellbore to adequately clean the inner surface of the casing. Additionally, multiple passes of the given wellbore cleaning tool may be required to ensure effective cleaning of the inner surface of the casing. Further, a combination of different wellbore cleaning tools are often used sequentially to fully clean and prepare the wellbore for the next phase of operations of the well system.

Particularly, a series of wellbore cleaning tools are often deployed or “run” into and retrieved from the wellbore sequentially, often in predefined sequence, to achieve a comprehensive cleaning operation. For example, after deploying a scraper tool to remove hard deposits from the casing, the scraper tool must be retrieved from the wellbore to the surface before a separate brush tool can be run into the wellbore to clean softer residues from the casing. Likewise, following the brushing operation, additional runs may be required to deploy baskets to collect debris and/or magnets to capture metal particles from the inner surface of the casing.

Often, wellbore cleaning tools have a single operational mode and thus comprise a scraper tool and only a scraper tool, a brush tool and only a brush tool, and so on and so forth such that an operator of the well system may need to possess a range of different wellbore cleaning tools at the wellsite in order to complete a wellbore cleaning operation of the well system. Additionally, well system operators may face significant logistical and operational challenges when required to maintain and deploy a variety of specialized wellbore cleaning tools to perform a comprehensive wellbore cleaning operation. For instance, the need to manage and utilize multiple distinct wellbore cleaning tools (e.g., scraper tools, brush tools, basket tools, and/or magnet tools) instead of a single integrated or multi-modal tool may undesirably increase inventory, transportation, maintenance, and storage requirements. In addition, different wellbore cleaning tools may vary by manufacturer, design, and configuration. This lack of standardization between different wellbore cleaning tools poses issues with tool compatibility where, for instance, different wellbore cleaning tools may not easily fit into the same deployment system or string configuration.

While some multi-modal wellbore cleaning tools have been developed, such existing multi-modal wellbore cleaning tools suffer from one or more issues that limit their applicability and usefulness in performing wellbore cleaning operations. Particularly, existing multi-modal wellbore cleaning tools often require specialized adapters and/or other accessories to ensure a proper fit or coupling between different engagement tools (e.g., scraper blades, brushes, baskets, magnets) and a sub or body used to carry and convey the engagement tools into the wellbore given that the size, shape, and other aspects of the configuration of the different engagement tools carried by the tool body may vary substantially. Moreover, such issues of fit, clearance, and support between the tool body and the different engagement tools may limit the efficacy and operability of the engagement tools and/or reduce the operational lifespan of the multi-modal wellbore cleaning tool.

Accordingly, embodiments of multi-modal wellbore cleaning systems and associated tools are described herein that include one or more engagement tools mountable on a tool sub or body using one or more corresponding tool connectors whereby an annular gap is formed between the engagement tool and the tool body such that direct contact between the engagement tool and the tool body is prevented and instead the engagement tool remains entirely spaced from the tool body. In some embodiments, one or more bearings are provided between the tool connectors and the tool body to permit relative rotation between the engagement tools and the tool body about a shared central axis thereof. The engagement tool may be trapped axially between a pair of the tool connectors such that relative axial movement between the engagement tool and the tool body is restricted while permitting the release of the engagement tool from the tool body whereby the engagement tool may be conveniently replaced (e.g., at the surface of a well system) with a separate engagement tool having different features or functionalities from the prior engagement tool. The engagement tools discussed herein may take a variety of forms including, for example, blade tools, brush tools, basket tools, magnet tools, deburring tools, drift tools, filter tools as well as other tools used for cleaning wellbores. It may be understood the exemplary engagement tools disclosed herein are not limiting on the breadth of engagement tools embraced by this disclosure.

Referring now to FIG. 1, a well system 10 is shown in which a wellbore 3 extends into a subterranean earthen formation 7. The wellbore 3 is a cased wellbore including a casing string 12 secured and sealed to an inner surface or sidewall of the wellbore 3 using cement. Casing string 12 may include a plurality of tubular segments or casing joints coupled together via a plurality of casing collars or joints. Exemplary debris 16 (e.g., cement, soft debris, ferrous debris) may be located irregularly along an inner surface 14 of the casing string 12, as will be discussed further herein.

Well system 10 additionally includes a surface assembly 11 positioned at the surface 5, and a tool string 18 deployed into the wellbore 3 from the surface assembly 11. Surface assembly 11 typically includes surface equipment suitable for drilling, completing, and/or operating well system 10. For instance, surface assembly 11 may include a wellhead, a casing hanger supporting casing string 12, derricks, rotary drives, slips, top drives, mud pumps, well control components 15 (e.g., electrical, mechanical, hydraulic components), etc. In this exemplary embodiment, tool string 18 comprises a bottom hole assembly (BHA) and thus may also be referred to herein as BHA 20. BHA 20 is suspended within wellbore 3 from tool string 18 that extends from surface assembly 11. Tool string 18 may comprise a drill string that includes a plurality of drill pipe joints threadably connected end-to-end at the surface assembly 11 (e.g., via a top drive or rotary table of the surface assembly 11) as the drill string is run into the wellbore 3. In other embodiments, tool string 18 may instead comprise a coiled tubing (CT) string that is extended from a CT reel of the surface assembly 11. In still other embodiments, tool string 18 may instead comprise conveyance mechanisms other than drill strings and CT strings such as wireline and the like. Similarly, in other embodiments, BHA 20 may comprise other types of tool strings used for performing various operations within the wellbore 3.

BHA 20 is generally configured to drill into or penetrate the subsurface region 7 to extend the wellbore 3 at a terminal end or toe (not shown in FIG. 1) thereof. In this exemplary embodiment, BHA 20 generally includes, for example, a drill bit 22, a downhole mud motor 24, and one or more wellbore cleaning tools 30. Drill bit 22 is configured to physically engage and drill into the subsurface region 7 while mud motor 24 is configured to facilitate the operation of drill bit 22 by driving the rotation of one or more cutting elements of the drill bit 22. Particularly, drilling fluid may be pumped from the surface assembly 11 (e.g., via one or more surfaces pumps thereof) through a central passage of the tool string 18 where it is received by the BHA 20. The flow of drilling fluid received by BHA 20 drives the rotation of a rotor of the mud motor 24 that is coupled to the drill bit 22 to drive the rotation thereof. The configuration of BHA 20 may vary in other embodiments. For instance, in other embodiments, BHA 20 may not include downhole mud motor 24 and/or may include additional components or tools (e.g., logging tools, steering tools) not shown in FIG. 1.

Although shown as part of BHA 20 in FIG. 1, in other embodiments, wellbore cleaning tool 30 may be positioned along the tool string 18 at one or more locations that are spaced from the BHA 20. Additionally, although only a single wellbore cleaning tool 30 is shown in FIG. 1, in other embodiments, BHA 20 and/or tool string 18 may include a plurality of separate wellbore cleaning tools 30. In this exemplary embodiment, wellbore cleaning tool 30 of BHA 20 includes one or more mandrels or bodies 32, and one or more engagement tools 34 coupled to and supported on the tool body 32. In some embodiments, engagement tool 34 is permitted to rotate about a central axis of wellbore cleaning tool 30 relative to the tool body 32 thereof while, in other embodiments, engagement tools 34 may be rotationally locked to the tool body 32 of wellbore cleaning tool 30. Additionally, in this exemplary embodiment, engagement tool 34 is releasably coupled to the tool body 32 such that engagement tool 34 may be conveniently and quickly replaced by a different engagement tool (e.g., at the surface 5 by personnel of well system 10) at the surface 5 that varies in configuration and functionality from engagement tool 34.

In some embodiments, engagement tool 34 comprises a blade or scraper that cuts into hardened debris 16 (e.g., cement) formed along the inner surface 14 of casing string 12 as the BHA 20 is run downhole to the terminal end of wellbore 3. Alternatively, engagement tool 34 may comprise a brush, a basket, a magnet, deburring tools, drift tools, filter tools and/or other engagement tools for removing debris 16 or otherwise cleaning the inner surface 14 of casing string 12. Through physically engaging the inner surface 14 of casing string 12 with engagement tool 34, the wellbore cleaning tool 30 forms a cleaned inner surface 14′ of casing string 12 extending uphole from the wellbore cleaning tool 30 that is generally free of debris 16. Additional downhole tools (not shown in FIG. 1) may subsequently (e.g., during a completion phase of well system 10) reliably seal against the cleaned inner surface 14′ of casing string 12 following the removal of BHA 20 and tool string 18 from wellbore 3. Additionally, production of hydrocarbons (e.g., during a production phase of well system 10) from the subsurface region 7 via wellbore 3 may be maximized by maximizing the flow area of casing string 12. In some embodiments, wellbore cleaning tool 30 may be retrieved to the surface 5 and a replacement engagement tool 34 may be coupled to the tool body 32 thereof for cleaning the inner surface 14 of casing string 12. This process may be repeated several times whereby a first run is made, for instance, with a scraper engagement tool, followed by a brush engagement tool, a basket engagement tool, and a magnet engagement tool.

Referring to FIG. 2, an embodiment of a multi-modal wellbore cleaning tool 100 is shown deployable into a wellbore extending through a subsurface region (e.g., wellbore 3 and subsurface region 7 shown in FIG. 1). Wellbore cleaning tool 100 has a longitudinal or central axis 105 and generally includes a tubular mandrel or tool body 102, an annular pair of tool couplers or connectors 130, and an engagement tool 140 coupled to the tool body 102 longitudinally between and through the pair of tool connectors 130. Additionally, in this exemplary embodiment, wellbore cleaning tool 100 includes an annular pair of bearings 120 coupled radially between the pair of tool connectors 130 and the tool body 102 whereby relative rotation about central axis 105 is permitted between tool connectors 130 (along with engagement tool 140 coupled with tool connectors 130) and the tool body 102. However, in other embodiments, wellbore cleaning tool 100 may not include bearings 120 and instead the tool connectors 130 and engagement tool 140 may each be rotationally locked to the tool body 102 such that relative rotation about central axis 105 between tool body 102 and each of the tool connectors 130 and engagement tool 140 is restricted. Further, in other embodiments, rather than being rotatably coupled between tool body 102 and tool connectors 130, bearings 120 may instead be rotatably coupled between tool connectors 130 and engagement tool 140 such that relative rotation about central axis 105 is provided between engagement tool 140 and tool body 102 while tool connectors 130 remain rotationally locked to the tool body 102.

Tool body 102 includes a pair of longitudinally opposed ends 104, a central bore or passage 106 extending between the pair of ends 104, and a generally cylindrical outer surface 108 also extending between the pair of ends 104. In some embodiments, the ends 104 of tool body 102 define connectors (e.g., threaded connectors) for coupling the wellbore cleaning tool 100 with other tools or tubular members (e.g., drill pipe joints, BHA components). Additionally, in this exemplary embodiment, a pair of annular grooves 110 are formed in the outer surface 108 of tool body 102 in which the bearings 120 and/or tool connectors 130 are received to axially lock the bearings 120 and tool connectors 130 to the tool body 102 such that relative axial movement along central axis 105 is restricted therebetween. For instance, the pair of ends 104 of tubular tool body 102 may be removeable from a central portion or section of tool body 102 whereby bearings 120 and tool connectors 130 may be axially slid or slipped onto annular grooves 110 of tool body 102 during assembly of wellbore cleaning tool 100.

As described above, bearings 120 permit relative rotation between tool connectors 130/engagement tool 140 and tool body 102 about central axis 105. While the configuration of bearings 120 may vary in different embodiments, in this exemplary embodiment, each bearing comprises an annular radially inner race 122, an annular radially outer race 124, and one or more bearing elements 126 (e.g., balls, rollers, and the like) positioned radially between races 122 and 124 to permit relative rotation about central axis 105 therebetween. In other embodiments, bearings 120 may not include bearing elements 126 and instead may comprise plain bearings or hydrodynamic bearings. Further, while wellbore cleaning tool 100 includes a pair of bearings 120 in this exemplary embodiment, alternatively, wellbore cleaning tool 100 may include varying numbers of bearings 120. For instance, in another embodiment, wellbore cleaning tool 100 may include three or more separate bearings 120 rotatably supporting three corresponding tool connectors 130 and a pair of engagement tools 140 coupled between the three tool connectors 130.

Tool connectors 130 couple or secure the engagement tool 140 to the tool body 102 whereby external loads applied to the engagement tool 140 (e.g., as a result between contact between engagement tool 140 and the inner surface of a casing string) are transferred to the tool body 102 via the tool connectors 130. In this exemplary embodiment, tool connectors 130 are supported on or otherwise coupled to bearings 120. For instance, tool connectors 130 may comprise a pair of C-shaped members that clamp onto the outer races 124 of bearings 120. Alternatively, tool connectors 130 may couple directly to the outer surface 108 of tool body 102 and/or other intervening members of wellbore cleaning tool 100. In this exemplary embodiment, each tool connector 130 comprises an interface or receptacle 132 (e.g., an annular groove) that extends into the tool connector 130 at a longitudinal end thereof. In other embodiments, tool connectors 130 may instead comprise interfaces in the form of projections that extend into corresponding receptacles formed in the engagement tool 140 for coupling the tool connectors 130 to the engagement tool 140.

The engagement tool 140 of wellbore cleaning tool 100 may comprise various types of tools for engaging and cleaning an inner surface of a casing or other tubular string. For instance, engagement tool 140 may comprise one or more blades, scrapers, brushes, baskets, deburring tools, drift tools, filter tools or other receptacles, and/or magnets. Additionally, engagement tool 140 is shown as annular in FIG. 2; however, in other embodiments, engagement tool 140 may not be annular and instead may be arcuate, planar, and/or other configurations. Additionally, engagement tool 140 extends longitudinally between a pair of opposing longitudinal ends 141 and includes a radially outer surface 142 extending between ends 141, and a corresponding radially inner surface 144 also extending between ends 141.

In this exemplary embodiment, the ends 141 of engagement tool 140 are captured or otherwise received in the receptacles 132 of tool connectors 130 to restrict relative axial movement between tool connectors 130 and engagement tool 140. Relative rotation is also restricted between engagement tool 140 and tool connectors 130 in this exemplary embodiment; however, in other embodiments, relative rotation or other movement may be permitted between tool connectors 130 and engagement tool 140. Additionally, in this exemplary embodiment, an annular gap 145 is formed between the radially inner surface 144 of engagement tool 140 and the outer surface 108 of tool body 102. Annular gap 145 extends longitudinally entirely between the pair of tool connectors 130 whereby no direct contact is made between engagement tool 140 and the tool body 102. In this manner, no friction occurs directly between engagement tool 140 and tool body 102 and the annular gap 145 provides sufficient radial clearance between engagement tool 140 and tool body 102 to permit engagement tool 140 to take on different shapes, sizes, and/or other configurations without entering into physical interference with the tool body 102. This flexibility permits various types of engagement tools 140 of different shapes and sizes to be releasably coupled via the tool connectors 130 to the same tool body 102 such that a given tool body 102 may be used with a variety of different engagement tools 140 having various features and functionalities. The flexibility of relying on only a single tool body 102 (or configuration of tool body 102) may reduce the amount of equipment an operator of a well system incorporating wellbore cleaning tool 100 may need to keep on hand at the wellsite.

As described above, engagement tool 140 may be releasably coupled to tool body 102 such that engagement tool 140 may be quickly and conveniently replaced (e.g., manually at the site of a well system) by a different engagement tool having different functionalities. For instance, in some embodiments, wellbore cleaning tool 100 may be assembled by coupling a first bearing 120 and tool connector 130 to the tool body 102, followed by axially sliding the engagement tool 140 over the tool body 102 whereby one of the ends 141 of engagement tool 140 is received in the receptacle 132 of the first tool connector 130. A second tool connector 130 may then be coupled to the tool body 102 such that the other end 141 of engagement tool 140 is received in the receptacle 132 of the second tool connector 130, thereby axially trapping the engagement tool 140 between the pair of tool connectors 130 coupled to the tool body 102. This process may be repeated in other embodiments including a plurality of engagement tools 140 (which may vary in configuration from one another) that are connected end-to-end via intervening tool connectors 130. For instance, if desired, a wellbore cleaning tool 100 in some embodiments may incorporate a first engagement tool 140 having, for example, a blade or scraper, a second engagement tool 140 having a brush, a third engagement tool having a basket, and so on.

Referring to FIGS. 3A and 3B, another embodiment of a wellbore cleaning tool 200 in accordance with principles disclosed herein is shown that is deployable into a wellbore extending through a subsurface region (e.g., wellbore 3 and subsurface region 7 shown in FIG. 1). Particularly, FIG. 3A is a schematic view of a first embodiment of a wellbore cleaning tool 200 in a scraper or blade configuration and FIG. 3B is an exploded view of the wellbore cleaning tool 200 of FIG. 3A. Wellbore cleaning tool 200 may include features in common with wellbore cleaning tool 100, and shared features are labelled similarly.

As shown in FIG. 3A, wellbore cleaning tool 200 generally includes a cylindrical mandrel or tool body 201 having a cylindrical outer surface 203, a pair of the tool connectors 230, an engagement tool in the form of a scraper or blade tool 240 coupled to the tool body 201 through a pair of tool connectors 230, and a plurality of annular bearings 202 coupled radially between the pair of tool connectors 230 and the tool body 201 allowing relative rotation between tool connectors 230 (along with blade tool 240 coupled with tool connectors 230) and the tool body 201. Additionally, in this exemplary embodiment, wellbore cleaning tool 200 includes a pair of alignment members or centralizers 250 that slide over and couple with the pair of tool connectors 230. In this exemplary embodiment, wellbore cleaning tool 200 also includes an annular central tool support member 210 for physically supporting and aligning blade tool 240, and a wear ring 220 such that each are each positioned along a shared central axis of the wellbore cleaning tool 200. While wellbore cleaning tool 200 features a blade tool 240, it should be understood that wellbore cleaning tool 200 may comprise other engagement tools as will be disclosed further herein.

Referring to FIGS. 4A, 4B, 4C, and 4D, exemplary schematic diagrams illustrating an exemplary process or method of assembling wellbore cleaning tool 200 is shown. Particularly, FIG. 4A is a schematic view of an exemplary tool body 201; FIG. 4B is a schematic diagram illustrating coupling of bearings 202 to tool connectors 230; FIG. 4C is a schematic diagram illustrating receiving of the coupled bearing 202 and tool connector 230 on the tool body 201; and FIG. 4D is a schematic diagram illustrating assembly of blade tools 240 on tool body 201. As shown particularly in FIG. 4A, tool body 201 includes a pair of longitudinally opposed ends 205, a central bore or passage 207 extending between the pair of ends 205, and a generally cylindrical outer surface 203 also extending between the pair of ends 205. Tool body 201 may comprise a tool body, or any other tubular member or support structure on which other components of wellbore cleaning tool 200 may be mounted. In some embodiments, the ends 205 of tool body 201 define connectors 209 (e.g., threaded connectors) for coupling wellbore cleaning tool 200 with other tools or tubular members (e.g., drill pipe joints, BHA tools, a CT string). Additionally, in this exemplary embodiment, tool body 201 includes a pair of the annular grooves 110 formed on the outer surface 203 of tool body 201 in which the bearings 202 and/or tool connectors 230 are received to axially lock the bearings 202/tool connectors 230 to the tool body 201 such that relative axial movement is restricted therebetween.

In this exemplary embodiment, a pair of bearings 202 are receivable within corresponding internal grooves 231 of sleeve or tool connector 230 as illustrated by arrows 410 in FIG. 4B. The assembly of bearings 202 received in grooves formed along the inner surfaces of sleeves forming tool connectors 230 may be referred to collectively herein as a retainer assembly 233. Referring briefly to FIG. 5B, a schematic view of an exemplary bearing 202 is shown. The bearing 202 may comprise an annular bearing comprising two halves, each half comprising a radially outer surface defining a radially outer groove 206, and a radially inner surface 204. Bearing 202 is configured to align and couple with a portion of tool connector 230 and/or centralizer 250. As previously described, bearing 202 may also include bearing elements (e.g., bearing elements 126 of FIG. 2). In some embodiments, bearings 202 may not include bearing elements 126 and instead may comprise plain bearings or hydrodynamic bearings. Referring briefly to FIG. 5A, an exemplary tool connector 230 is shown. In this exemplary embodiment, tool connector 230 comprises a generally cylindrical body 234 having a pair of C-shaped members 236, and a receptacle 232. Each C-shaped member 236 is configured to clamp onto the outer surfaces of bearings 202 as shown in FIG. 4C.

FIGS. 4C and 4D show an exemplary tool assembly of wellbore cleaning tool 200. FIG. 4C is a schematic view of the coupled tool connector 230 and bearing 202 assembly, being aligned with one of the pair of annular grooves 110 formed on the outer surface 203 of tool body 201. Each half of the coupled tool connector 230 and bearing 202 assembly may be mounted onto annular groove 110 using one or more fasteners 235 (e.g., pin, bolts, screws). As shown particularly in FIG. 4D, the two halves of the coupled tool connector 230 and bearing 202 assembly may be mounted and axially aligned on a first annular groove 110, and then secured in place using the fastener assembly. In this exemplary embodiment, a first centralizer 250 is slid over the coupled tool connector 230 and bearing 202 assembly and secured in place. In some embodiments, the centralizer 250 may be secured to the tool connector 230 using fasteners such as bolts, pins, screws or a combination thereof. In some embodiments, a pair of blade tools 240 is slid onto outer surface 203 to engage with tool connector 230 and centralizer 250. In this exemplary embodiment, and as shown particularly in FIG. 3B, centralizers 250 include a first or uphole end and a longitudinally opposed second or downhole end, where an annular groove 252 radially surrounds the downhole end. In some embodiments, the annular groove 252 may be formed in the uphole end of at least one of the centralizers 250.

Referring briefly to FIG. 5C, an embodiment of an exemplary blade tool 240 is shown. Blade tool 240 is an engagement tool that is releasably coupled to the tool body 201 such that blade tool 240 may be replaced by a different engagement tool (e.g., brush tool, basket too, magnet tool) that varies in configuration and functionality from blade tool 240. Blade tool 240 comprises a generally cylindrical blade body 242 extending from a first end 243 to a longitudinally opposed second 245, an inner surface 244, a plurality of blade or scraper elements 246 for scraping the inner surface of a casing or tubing (e.g., inner surface 14 of casing string 12 shown in FIG. 1) and a split 248 for locking blade tool 240 to tool connector 230. In some embodiments, blade tool 240 may comprise a single piece or a plurality of pieces machined together. In certain embodiments, blade tool 240 may comprise components and configurations not shown in FIG. 5C. In some embodiments, blade tool 240 comprises blade elements 246 that cuts into hardened debris 16 (e.g., cement) formed along the inner surface of a casing or tubing as the BHA 20 is run downhole to the terminal end of a wellbore (e.g., wellbore 3 of FIG. 1). Each blade tool 240 may be machined from a piece of steel or any other metal with split 248. The split 248 allows the blade tool 240 to flex and adapt to the inner surface of the casing or a tubular wall. Additionally, blade tool 240 includes rows of blade elements 246. In some embodiments, blade elements 246 comprises a plurality of machined teeth and slotted holes that eliminate the chance of debris becoming trapped between the blade tool 246 and tool body 201.

Referring back to FIG. 4D, in this exemplary embodiment, the first end 243 of a first blade tool 240 is aligned and engage with a receptacle (e.g., annular groove or receptacle 232 of FIG. 2) that extends into tool connector 230. In this manner, an annular gap (e.g., annular gap 145 of FIG. 2) is formed between the radially inner surface 244 of blade tool 240 and the outer surface 203 of tool body 201. In some embodiments, a pair of blade tools 240 may be coupled to tool body 201. Annular gap 145 extends longitudinally entirely between tool connectors 230 whereby no direct contact is made between blade tool 240 and the tool body 201. In this manner, no friction occurs directly between blade tool 240 and tool body 201 and the annular gap 145 permits blade tool 240 to take on different shapes, sizes, and/or other configurations without entering into physical interference with the tool body 201. In some embodiments, a wear ring 220 is installed between the tool connector 230 and/or centralizer 250 and the blade tool 240 as an added protective barrier that absorbs friction. Additionally, a central tool support member 210 may be positioned between the pair of blade tools 240 to provide stability in the tool assembly.

Referring to FIGS. 6A-6C, another embodiment of a wellbore cleaning tool 300 in accordance with principles disclosed herein is shown that is deployable into a wellbore extending through a subsurface region (e.g., wellbore 3 and subsurface region 7 shown in FIG. 1). Particularly, FIG. 6A is a schematic view of a second embodiment of a wellbore cleaning tool 300 in a brush configuration; FIG. 6B is a schematic view of an exemplary brush cage of the wellbore cleaning tool 300 of FIG. 6A; and FIG. 6C is a schematic view of an exemplary brush element 344 of the wellbore cleaning tool 300 of FIG. 6A. Wellbore cleaning tool 300 may include features in common with wellbore cleaning tool 100 and 200 described above, and shared features are labelled similarly.

Referring to FIG. 6A, wellbore cleaning tool 300 generally includes tool body 201, an annular pair of tool couplers or connectors 230, and an engagement tool in the form of a brush tool 340 coupled to the tool body 201 through the pair of tool connectors 230 and/or centralizers 250. The brush tool 340 comprises a brush cage 342 and a plurality of brush elements 344 (shown in FIG. 6B) for removing debris, mud, and other unwanted material from the inner surface of a casing or tubing (e.g., inner surface 14 of casing string 12 shown in FIG. 1). In some embodiments, the brush tool 340 comprises a single member or a plurality of members coupled together. In some embodiments, wellbore cleaning tool 300 may also include a thread protector.

Referring now to FIGS. 7A and 7B, another embodiment of a wellbore cleaning tool 400 in accordance with principles disclosed herein is shown that is deployable into a wellbore extending through a subsurface region (e.g., wellbore 3 and subsurface region 7 shown in FIG. 1). Particularly, FIG. 7A is a schematic view of a third embodiment of a wellbore cleaning tool 400 in a magnet tool configuration, and FIG. 7B is an exploded view of the wellbore cleaning tool 400 of FIG. 7A. Wellbore cleaning tool 400 may include features in common with wellbore cleaning tools 100, 200, and 300 described above, and shared features are labelled similarly.

As shown in FIGS. 7A and 7B, wellbore cleaning tool 400 generally includes tool body 201 comprising an outer surface 203 and a pair of the annular groove 110 disposed on the outer surface 203, bearings 202, an annular pair of tool couplers or connectors 430, centralizers 250, central tool support member 210, and a plurality of circumferentially spaced engagement tools in the form of magnets 440 (e.g., permanent magnets) coupled to the tool body 201 through the pair of tool connectors 430 and/or centralizers 250 along with a pair of annular magnet supports 460. Additionally, wellbore cleaning tool 400 includes one or more magnet holders 450 receivable within the central tool support members 210 in this exemplary embodiment for rotationally locking the plurality of circumferentially spaced magnets 440 to the tool connectors 430 and central tool support members 210. In this manner, the magnets 440 of wellbore cleaning tool 400 may capture metal particles from the inner surface of the casing (e.g., inner surface 14 of FIG. 1

Referring now to FIG. 8, another embodiment of a wellbore cleaning tool 500 in accordance with principles disclosed herein is shown that is deployable into a wellbore extending through a subsurface region (e.g., wellbore 3 and subsurface region 7 shown in FIG. 1). Particularly, FIG. 8 is a schematic view of a fourth embodiment of a wellbore cleaning tool 500 in a basket tool configuration. Wellbore cleaning tool 500 may include features in common with wellbore cleaning tools 100, 200, 300, and 400 described above, and shared features are labelled similarly. Particularly, in this exemplary embodiment, wellbore cleaning tool 500 includes tool body 201, one or more bearings 202, one or more tool connectors 230, one or more centralizers 250, and a basket tool 510 supported by the tool body 201 through the tool connectors 230. Basket tool 510 defines an internal chamber or compartment (e.g., an annular chamber) for trapping loose wellbore debris via one or more radial openings or slots 512 positioned along the basket tool 510.

Referring to FIG. 9, an embodiment of a method 550 for providing a wellbore cleaning tool (e.g., wellbore cleaning tools 30, 100, 200, 300, 400, and 500 shown in FIGS. 1, 2, 3A and 3B, 6A-6C, 7A and 7B, and 8, respectively) deployable into a wellbore (e.g., wellbore 3 shown in FIG. 1) extending through a subsurface region (e.g., subsurface region 7 shown in FIG. 1). At block 552, method 550 comprises providing a tool body (e.g., tool bodies 32, 102, and 201 shown in FIGS. 1, 2, and 3A and 3B, respectively) comprising an annular upper groove and an annular lower groove (e.g., annular grooves 410 shown in FIGS. 4C and 4D) spaced along a longitudinal length of the body.

At block 554, method 550 comprises coupling one or more bearings (e.g., bearings 202 shown in FIGS. 4C and 4D) to sleeves of a plurality of retainer assemblies (e.g., retainer assembly 233 shown in FIG. 4B). At block 556, method 550 comprises mounting the plurality of retainer assemblies on the upper groove and the lower groove of the tool body. At block 558, method 550 comprises coupling one or more centralizers (e.g., centralizers 250 shown in FIG. 4D) to the plurality of retainer assemblies, each of the one or more centralizers comprising a first end and a longitudinally opposed second end, wherein the second end comprises an annular groove radially surrounding the second end, and wherein the annular groove is downhole from the first end. At block 560, method 550 comprises sliding an engagement tool (e.g., engagement tools 34, 140, shown in FIGS. 1 and 2, respectively) over the centralizer, wherein a portion of the engagement tool is received in the annular groove and the engagement tool is configured to clean an inner surface of a tubular member positioned in the wellbore.

Relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.