SPE 101727
Reliable and Effective Downhole Cleaning System for Debris and Junk Removal
D.B. Haughton and P. Connell, Baker Oil Tools
Copyright 2006, Society of Petroleum Engineers
This paper was prepared for presentation at the 2006 SPE Asia Pacific Oil & Gas Conference
and Exhibition held in Adelaide, Australia, 11–13 September 2006.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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Abstract
Wellbore debris is responsible for many of the problems and
much of the extra costs associated with producing wells,
especially in extreme water depths and highly deviated holes.
Even a small piece of debris at the right place at the wrong
time can jeopardize well production. For this reason, debris
management has become a chief concern for oil and gas
producers. Considering rig rates and completion equipment
costs, debris removal is moving into the realm of risk
management.
A clean wellbore is not only a prerequisite for trouble-free
well testing and completion; it also helps ensure optimum
production for the life of the well. Debris left in the wellbore
can ruin a complex, multi-million dollar completion; it can
prevent a completion from reaching total depth. And chances
are, it will never reach an optimum production level.
These issues are pushing the industry to create reliable,
efficient systems for quickly ridding wellbores of harmful
debris and larger pieces of junk. This paper describes a
vectored annular cleaning system (VACS) that can be used
alone or in conjunction with any of an assortment of improved
casing scrapers, brush tools, downhole magnet subs, downhole
filter tools and junk catchers to optimize the efficiencies and
economics of debris removal and save trips.
This paper will focus on the use of the vectored annular
cleaning system to collect and remove debris from areas of the
wellbore that traditionally are problematic; i.e., above liner
tops, where casing size changes, areas with a loss of annular
velocity, and wells with little to no circulation. Case histories
from the Gulf of Mexico, North Sea and other areas of the
world will demonstrate how this technology has reduced
problems of debris removal while saving rig time by
eliminating trips.
Introduction
The problems that arise from the drilling phase of a well range
from lost bit cones and hand tools dropped in the wellbore to
debris remaining after drilling out float equipment. Most tools
run today to fish bit cones use a reversing-type flow that is
designed to lift the cones into a finger-type catcher. Debris
created when drilling out float equipment can cause the drill
bit to fail or cause premature wear to the drill bit if left in the
wellbore and not fully circulated out or recovered.
During the completion phase, the most common form of
debris is caused by perforating guns. Many wells are shot at
multiple zones and usually have a retrievable bridge plug or
packer plug below the perforated area to isolate the different
zones. Once the guns are fired and removed, a large amount of
gun and perforating debris settles around the retrieving heads
of the packer plugs or bridge plugs. Debris is a primary barrier
to retrieval of the packer plug. Although the packer plug
retrieving head contains milling teeth and fluid passages to
mill away any sand or settlings from around the control bar,
experience has shown that metal shavings and junk do not
permit full engagement of the J-pin in the internal slot. Also,
once the packer plug is retrieved, there is a high probability of
debris falling into the lower completion. This becomes costly
and may be very time consuming, sometimes requiring more
than one trip to recover the plugs.
Some debris remains suspended in the wellbore, in the fluid,
casing collars and/or liner tops. This debris, if not removed,
will cause problems during running of the completion string.
Despite precautions to keep the production equipment as clean
as possible, it is common to find problematic metal debris and
shavings in the production string after the completion is run.
The debris can cause difficulty during subsequent slickline
operations to gain access to equipment further down the well.
Furthermore, the risk of slickline tools and equipment
becoming stuck is increased, often necessitating costly fishing
operations.
Coiled tubing, with its ability to circulate fluids, is often used
to address debris problems once they are recognized. These
runs, require cleanout fluids and downhole tools to clean out
the production tubing. They also require manipulation of flow
control devices such as shifting sleeves, and recovery of
isolation plugs, all of which can become costly. Although less
likely than wireline, coiled tubing also carries a risk of
becoming stuck in a debris-laden completion, particularly in
2 SPE 101727

larger completion sizes where annular velocities may be

limited by size and flow capacity of the coiled tubing.

During workover operations where a permanent packer must

be removed by milling, the debris may cause many unforeseen
problems. It may damage the casing wall while milling or
cause the milling string to become stuck. On deepwater
floating rigs, the debris may become lodged in the subsea BOP
stack and hinder BOP operation. It can also create problems
when running the new completion string.

Operation/Applications

The vectored annulus cleaning system was originally designed

to capture cuttings downhole and prevent metal debris and
junk from reaching the surface during milling operations.
(Figure 1) It consists of a special milling head or tool, a debris
chamber, diverter tube, special screen, the jet bushing or
engine and top sub. The system resembles a plug-and-play
platform in that parts can be easily adapted and manipulated to
address a wide range of debris or junk removal needs as
dictated by the specific application. This ability is depicted in
the VACS platform chart in Figure 2.

Among applications for which the VACS is suited is cleaning

the casing exit window after a whipstock sidetracking
operation. The system can be run with a mule shoe or open-
ended clean-up mills to recover the metal shavings and cutting
debris collected around the window opening and whipstock
body. The system can recover retrievable packer plugs after
fracing or perforating jobs. It can recover lost junk such as bit
cones and loose junk that may otherwise cause premature
dulling of a drill bit. It can also clean liner tops prior to
completion to eliminate pieces of junk that could fall on top of
the completion packer or tools while running them in the
wellbore and cause them to set prematurely.

Fig. 1: Vectored-Annulus Cleaning System

SPE 101727
Fig. 2 VACS Platform Chart
The cleaning system can remove settled-out debris from the
tops of corrosion caps that have been left after a temporary
abandonment. With the tools working much like a
contemporary household vacuum cleaner, applications vary
infinitely.
The system does not require high pump rates or special fluid.
It works the same in fresh-water or very highly weighted mud
systems.
3
When fluid is pumped through the system (See Fig.1) and out
of the nozzles (standard size is 3/16-in., but a larger size can
be used), a vacuum is created at the jet bushing chamber that
causes fluid and debris to be sucked from the wellbore. With
the reduced ID in the diverter area, the fluid has a high
velocity. Velocity decreases as the fluid moves out of the
diverter tube because of the increase in tool ID. Larger and
heavier particles then fall out into the debris chamber, while
smaller and lighter particles are filtered by the screen section
4 SPE 101727
above. When circulation is stopped, the small particles are
caught in the debris chamber. The deflector at the top of the
diverter tube prevents the particles from exiting the bottom of
the tool. Filtered fluid is re-circulated into the wellbore.
Standard operating procedure when using the vectored-
annulus cleaning system to capture debris while milling or
cutting is as follows.
1. Position the VACS within 60 to 120 ft above the
milling or cutting assembly. (See Fig. 3).
2. Trip tool into well to approximately 2-3 stands above
the top of debris and break circulation.
3. Once circulation is established, start slowly washing
down. When the top of the debris has been
determined, continue washing while reciprocating the
string.
4. Establish normal cutting and milling procedures for
the particular application being performed.
5. During milling and cutting operations, the
cuttings/debris will travel up through the center of the
cutting or milling tool, up through the diverter tube
where the cuttings will fall out as the milling fluid
flows through the screen, and out the jet bushing.
Downhole magnets and boot baskets are run to help pick up
debris while tripping in the hole. The magnets also catch
debris that is small enough to pass through the screen section
of the cleaning system. It is very important to size the screen
accordingly to the size debris that will be recovered. If the
screen section is sized improperly, the debris will pass through
the screen and up hole. The purpose of the screen is to stop the
debris from moving up hole while still permitting circulation
of fluid through the tool.
Figure 4 shows cuttings and cement recovered during a
milling operation. This was produced while testing the system
by milling cemented-up casing.
Velocity and Flow Rate Calculation Spreadsheet
The engine of the vectored annulus cleaning system is the jet
bushing. Consideration should be given to the fluid conditions
in which the tool will be operating, since fluid weight and
viscosity are crucial to optimizing the efficiency of the jet
bushing. Generally, standard bit nozzles installed are 3/16-in.
size. The system operator should consider replacing these
nozzles with a size that is more compatible with the fluid type,
weight and viscosity of each job before running the cleaning
system in the well. Calculations software has been developed
to aid the engineer in the job design phase,. The software
calculates optimum flow rate and jet size for the system.
Spreadsheet inputs include the following.
• Nozzle diameter
• Fluid viscosity
• Diverter OD and ID
• Washpipe ID
• Net settling velocity
• Mill port diameter (if run)
• Particle diameter and weight (if known)
• Hole size
• Drill pipe and drill collar specifications
Calculation software outputs include the following.
• Required length of debris chamber
• Stand pipe pressure
• Required pump rate
• Anticipated cuttings volume
SPE 101727
Case History 1 - GULF OF MEXICO – USA
The VACS was mobilized from the port of Fourchon,
Louisiana, for a deepwater project that required gathering sand
and other debris from above a retrievable plug to and
retrieving the plug in the same trip as the cleanout. This job
was performed in 8 5/8 in., 49 lb/ft casing. A 5.360 in. OD
cleaning system was used in combination with a J- latch plug
retrieving tool that functioned as both a washover shoe and a
retrieving tool. Tools were picked up and run to a depth of
19,750 ft, which was 44 ft above the first perforations. Using
calculated velocity and flow calculations of two bpm and 20
RPM, parameters were established and recorded. Pumping and
rotation were then stopped, and the tool string was slacked off
from a depth of 19,976 ft to 20,009 ft, where fill was tagged.
Circulation was then established at 2 bpm, the string was
rotated at 20 RPM, and fill was washed while rotating to a
depth 20,036 ft. Rotation was stopped, and the work string
was washed down to 20,042 ft. At this point,, 15 K was
slacked off and then picked up, circulation was increased to 3
bpm, and weight of 20 K down was applied. A 20- K overpull
was applied to ensure that the plug had been engaged and then
slacked off. A 10 BBL sweep was pumped at a rate of 6 bpm
while the well was being monitored. Jars were bled open, the
plug bypass was sheered open, and the plug released and
5
pulled out of hole. Upon reaching surface, tools were laid out
and then broken down and 106 lbs. of sand recovered.
Case History 2 - NORTH SEA -Aberdeen
For this job, a VACS mobilized from Aberdeen, Scotland.,
was used after a frac job to ensure that debris was removed
from the hole before running gravel pack screens. The job
was performed using a 5.360 in. OD tool with 311 m of 2-
7/8–in. tubing attached for snorkel pipe and a 4 1/8-in.OD
muleshoe on bottom to gather debris. The cleaning system was
run in 7.00–in. casing as the OD of the tool prevented it from
being used in the 5.00–in. liner below. The top of the 5.00–in.
liner was at 2092 m with perforations from 2357 m to 2372 m.
The fishing assembly was picked up and run in hole;
calculated velocities and flow volumes were applied, and
parameters were recorded at 200 gpm with a standpipe
pressure of 3200 psi using sea water. Rotation was established
at 20 RPM to reach the working depth of 2375m. After
circulating for ½ hour, the tools were pulled out of hole. Upon
reaching surface, the tools were laid out and 195 kg of sand
were recovered to surface. Screens were then run and landed
at 2375 m.
6 SPE 101727
Case History 3 - NORTH SEA - Aberdeen
This application was performed using a 7 5/8-in. OD VACS
after a milling job where 1,500 ft of 5.00–in., 19.5 lb drillpipe
had been milled. The bottomhole assembly contained an 8 ½-
in. scalloped bottom shoe with 20 ft of 8 1/8–in. OD washpipe
extensions run below the cleaning system. Tools were picked
up and run in the hole to 16,679 ft. Fluid velocities and
volumes with the 12-pound mud had been calculated and were
applied. Parameters were recorded at 214 gpm with a
standpipe pressure of 3150 psi and 60 rpm as tools were
rotated and washed down to 16,869 ft. then circulated
“bottoms-up” slug pipe and pulled out of hole. Upon reaching
surface, tools were laid out and broken down. 1,345 lb of
metal debris were recovered to surface. See Figure 5.
Case History 4 - GULF OF MEXICO - USA
A VACS mobilized from Pascagoula, Mississippi, was used
after a PDC bit was pulled from the hole as a result of
decreased penetration rate. It was discovered that a piece had
broken off the PDC bit, leaving a full PDC button in the hole.
7 5/8-in. casing was set down to 19,380 ft with 8 ½-in. open
hole to 19,715 ft and 6 ½-in. open hole to 19,800 feet below
the casing. The team decided to run the cleaning system in the
7 5/8–in. casing due because of formation properties in the 8
½-in. open-hole section. As a result, 483 ft of 4.00 in. drillpipe
were picked up and deployed between the VACS and the 6
3/8–in. open hole. A rough OD shoe with finger-type catchers
was run on bottom. Tools were picked up and run in hole to
19,705 ft. Calculations for flow rates and volumes were
applied at 3.7 bpm at 1450 psi standpipe pressure with the
available 17.2 lb/g synthetic mud along with rotation of 20 to
40 rpm. Tools were washed past the top of the 6 ½-in. open-
hole section at 19,715 ft to 17,999 ft, where the hole circulated
for 20 minutes. Circulation was then was increased to 4.8 bpm
for 40 minutes, after which the pipe was slugged and pulled
out of hole. Upon reaching surface, the tools were laid out and
broken down. 10 lb of aluminum, a few small pieces of metal
and a PDC button were recovered. The 10 lb of aluminum
were the result of a junk shot that had been fired earlier in the
9 ½-in. open-hole section; the customer had been unaware that
it was there. See Figures 6 & 7.
Case History 5- GULF OF MEXICO – USA
A major company was having difficulties attempting to snap
their sand control equipment into a sump packer. After several
attempts to deploy the screen assembly without success, the
VACS was run in the wellbore with a mule shoe attachment at
bottom and a snap latch to verify that the sump packer was
clean. The tool was run and circulation was started at 3 bpm
approximately 200 ft above the sump packer and washed to
the sump packer. The sump packer was then latched into and
verified that it was clean. Total circulation time was 1 hour.
Once out of the hole, the VACS chamber was cleaned and
approximately 150 lb of debris was recovered, mostly from
TCP guns.
Conclusions
In some applications, the use of the vectored annulus cleaning
system necessitated innovative deployment of tools and
equipment. The following advantages and benefits are now
being realized as a result of testing, application, experience
and lessons learned:
• Reduced non-productive time (NPT)
• Reduced mud costs
• Subsea BOPs kept clean of cuttings
• Metal cuttings do not become suspended in the
drilling or milling fluid
• Cutting captured during milling operations
• All cuttings trapped in the junk basket or downhole
• Applicable with all cutting and non-hydraulic milling
tools
• Large amounts of debris removed from bottom of the
well
• Performance immune to mud yield, viscosity and
high flow rate
• Cuttings easy to collect in holes with large annulus or
high angles without having complex mud properties
Further development of system tools and equipment to
complement the vectored annulus cleaning system are
ongoing. The plug-and-play ability of a wide range of
accessory tools and equipment allows a simple yet customized
assembly to provide fit-for-purpose clean-out solutions (see
Fig. 2).
Acknowledgements
The authors would like to thank Baker Oil Tools for
permission to publish this paper.
SPE 101727 7

References

- Baker Oil Tools Tech Unit N.5665, "S-1 Latching

Type Packer Plug, Wash-Over Type Retrieving Head,
and Locator-Type Packer Plug", Baker Hughes Inc.,
Draft #1, 2004.
- Baker Oil Tools, “FISHING SERVICE
CATALOGUE – Junk Retrieval Tools Section”,
Baker Hughes Inc. 2001 – Pub. No. BOT-01-1486-
20M-5/01
- Baker Oil Tools, “ The Custodian™ One-Trip
Wellbore Cleaning System”, Baker Hughes Inc. 2002
– BOT-02-2875 4M 11/02
- Baker Oil Tools Tech Unit N.4680, "VACS ™Junk
Basket", Baker Hughes Inc., REV.D, 30 April 2004
8 SPE 101727

DrillPipe

Bumper / Fishing Jar

Downhole Magnets

Boot Baskets

VACS System

Special Mill

Fig. 3 Typical BHA Configuration for Milling

SPE 101727 9

Fig. 4 – Cuttings Recovered with VACS System

during Testing Fig. 6 – Debris Recovered Case History # 4

Fig. 5 – Debris Recovered Case History # 3

Fig. 7 – Debris Recovered Case History # 4