Ultrasound based technology for removal of scale from downhole production tubing, an experimental verification

Deposition and blockages due to scale formation inside the production tubing are the most common problems experienced during the production of oil and gas, and this significantly leads to a decline in the production rate. Progressive scale formation limits production which subsequently leads to abandonment of the well. There is a great cost attached to preventing the occurrence and remediation of scales. Chemical and mechanical techniques for scale removal in production tubing have drawbacks like environmental concerns, equipment damage, and incomplete removal of stubborn scale. In contrast, ultrasound-based methods offer potential benefits such as non-destructiveness, enhanced efficiency, reduced chemical usage, and increased safety for workers. Despite the extensive research about the application of ultrasound to improve oil recovery, there remains a significant gap in the comprehensive exploration of optimum ultrasound parameters (frequency, power, radiation time, interval time, and location) for the removal of in-situ built scales in a simulated production tubing under different flow rates. This study addresses this gap by investigating the impact of ultrasound parameters on its performance for removal of calcium carbonate (CaCO3) and gypsum scales in a simulated production tubing system under different flow rate (100% and 50%). The ultrasound parameters include frequency (in the range of 20 kHz–120 kHz), power (50 W and 100 W), operation time, and location (externally attached and inserted into the production tubing). Initial tests revealed that adjusting the operating frequency improves the impedance matching, resulting in enhanced scale removal. The experiments also explored the influence of flow rate on scale removal, showing a general increase in removal with higher flow rates, specially at operating frequencies 20 kHz and 28 kHz. It was also demonstrated that the higher frequencies of 40 kHz, 68 kHz, and 120 kHz exhibit limited removal efficiency. The effectiveness of scale removal exhibited nonlinear variation over time, with the 28 kHz, 100 W transducer demonstrating the most significant improvement. In-pipe ultrasonic rod, operating at a constant frequency of 26 kHz, was employed to assess its performance for scale removal. Pulsed treatment was introduced to manage rod heating issues. Results demonstrated that both interval times and flow rates influenced CaCO3 removal, with shorter intervals yielding better results. The ultrasonic rod's efficacy was also observed in removing gypsum scale layers, suggesting potential applications in treating scales with various strengths. The results of this study can contribute to a better understanding of how the frequency, power, operating time and interval, and flow rate influence ultrasonic scale removal. The experimental findings provide valuable insights in optimizing practical applications for removal of scales from production tubing.