Multi-cycle wellbore clean-out tool

Abstract

A clean-out tool and method of cleaning out a wellbore. The clean-out tool is placed at the end of a coiled tubing or other conveyance string. The clean-out tool comprises a tubular housing providing an elongated bore through which fluid flows. The tubular housing has back-jetting ports disposed at an upward angle therein. The clean-out tool is configured to operate in a back-jetting mode when the clean-out fluid is pumped into the tubular housing at a first flow rate. In this mode, at least a portion of clean-out fluid flows through the bore, up an annular region and then through the back jetting ports. The clean-out tool is further configured to operate in a fluid flow-through mode when the clean-out fluids are pumped into the bore of the tubular housing at a second flow rate. In this mode, all of the clean-out fluid flows through the clean-out tool.

Claims

1. A multi-cycle clean-out tool for controlling a direction of a clean-out fluid within a wellbore, the wellbore having been lined with a string of production casing, and the clean-out tool comprising: a tubular housing providing an elongated bore through which fluids may be injected, the tubular housing having one or more back jetting ports; a piston disposed at an upstream end of the tubular housing, the piston forming a pressure shoulder and having an orifice configured to deliver clean-out fluid from a wellbore conveyance tubing to the elongated bore of the housing; a tubular mandrel slidably positioned within the housing, the mandrel having a proximal end connected to or acted upon by the piston, and an open distal end forming a plunger; one or more radial slots disposed along the plunger; and a seat disposed along the tubular housing below the distal end of the tubular mandrel, the seat being configured to slidably receive the plunger when the piston and connected tubular mandrel slide from a raised position providing a back-jetting mode wherein the radial slots are above the seat, to a lowered position providing a flow-through mode wherein the radial slots are along or below the seat; and wherein the clean-out tool is configured to cycle a position of the mandrel and connected plunger in response to changes in fluid pumping rate into the conveyance tubing, with the mandrel and connected plunger moving between the back-jetting mode wherein at least a portion of the clean-out fluid flows through the back jetting ports, and the flow-through mode wherein the clean-out fluid flows entirely through the plunger and below the seat.

2. The wellbore clean-out tool of claim 1, wherein the plunger is configured to move in telescopic relation to the seat in response to the changes in fluid pumping rate.

3. The wellbore clean-out tool of claim 2, wherein the tubular housing comprises: an upper sub having a first upper end and a second lower end; and a lower sub having a first upper end abutted to the seat, and a lower end threadedly connected to a downhole tool.

4. The wellbore clean-out tool of claim 3, wherein the downhole tool is (i) a hydraulic nozzle, (ii) a bridge plug, (iii) a sliding sleeve shifting tool, or (iv) a positive displacement motor.

5. The wellbore clean-out tool of claim 2, wherein: a lower annular region is formed between the mandrel and the surrounding tubular housing providing fluid communication between the elongated bore of the tubular housing and the back jetting ports; the plunger defines a tubular body having an outer diameter; the through opening of the seat comprises an inner diameter dimensioned to closely receive the outer diameter of the plunger; and at least a portion of the plunger overlaps with the through-opening of the seat when the piston and connected mandrel are in the raised position.

6. The wellbore clean-out tool of claim 2, wherein: the at least one radial slot comprises a plurality of radially-disposed slots; and an inner diameter of the plunger below the radial slots is tuned to adjust a flow split of clean-out fluid between the back jetting ports and the seat while the clean-out tool is in its back-jetting mode.

7. The wellbore clean-out tool of claim 6, wherein: a lower end of the plunger is completely closed off to flow; and the radially-disposed slots reside above the lower end of the plunger such that all clean-out fluid flows back through the back jetting ports when the clean-out tool is in its back-jetting mode.

8. The wellbore clean-out tool of claim 2, wherein: the wellbore further comprises a string of production tubing; and the clean-out tool is dimensioned to be run into or through the string of production tubing.

9. The wellbore clean-out tool of claim 2, further comprising: a spring residing in an upper annular region between the tubular mandrel and the surrounding tubular housing above the lower annular region, the spring being pre-loaded in compression to bias the mandrel and connected plunger in the back-jetting mode; and a sequencing mechanism comprising a cylindrical body, wherein the sequencing mechanism is responsive to a sequence of the fluid pumping rates applied above the piston; and wherein at least one of the one or more back jetting ports is disposed along the tubular housing at an upward angle.

10. The wellbore clean-out tool of claim 9, wherein the sequencing mechanism is configured to cycle the mandrel and connected plunger between: its raised position wherein the clean-out tool is in the back-jetting mode; an intermediate position wherein the clean-out tool remains in its back-jetting mode, and its lowered position wherein the clean-out tool is in its flow-through mode.

11. The wellbore clean-out tool of claim 10, wherein: the sequencing mechanism is a J-slot sequencing mechanism; the J-slot sequencing mechanism cooperates with at least one pin disposed along the tubular housing configured to ride in slots along the cylindrical body to cycle the mandrel and connected plunger between the raised position, the intermediate position and the lowered position; and wherein the pin is fixed from axial movement and rides in J-slots of the mandrel to restrict axial movement of the mandrel on alternating downward strokes.

12. The wellbore clean-out tool of claim 11, wherein the J-slot mechanism and spring are configured to: (i) maintain the mandrel and connected plunger in its raised position while pumping at or below a first pump rate, placing the clean-out tool in the back-jetting mode wherein at least a portion of the clean-out fluid flows through the mandrel, up the lower annular region, and through the back jetting ports; (ii) maintain the mandrel and connected plunger in its intermediate position while increasing pump rate above the first pump rate, wherein the clean-out tool remains in its back-jetting mode; (iii) upon dropping the pump rate back down to or below the first pump rate, maintaining the mandrel and connected plunger in its raised position; (iv) upon raising the pump rate to a rate that meets or exceeds a second pump rate, move the mandrel and connected plunger to its lowered position, placing the clean-out tool in its flow-through mode wherein all clean-out fluid is forced to exit below the seat and downstream of the clean-out tool; and (v) repeat the cycle of steps (i) through (iv).

13. The wellbore clean-out tool of claim 11, wherein the J-slot mechanism is configured to cycle between three settings, comprising: (i) a first setting wherein the pin resides in a first slot that places the mandrel and connected plunger in the raised position in response to the biasing mechanical force exerted by the spring on the mandrel while pumping at a first rate, placing the clean-out tool in its back-jetting mode; (ii) a second setting wherein the pin moves higher in the first slot in response to the injection of the clean-out fluid into the conveyance tubing at an increased pump rate, while the plunger remains in intermediate position that keeps the clean-out tool in its back-jetting mode; (iii) the first setting again wherein the pin resides in a second slot that keeps the plunger in the raised position in response to the biasing mechanical force exerted by the spring; and (iv) a third setting wherein the pin moves higher in a third slot in response to the injection of the clean-out fluid into the conveyance tubing at a second increased rate, or at any rate higher than the second rate, and wherein the plunger slides from the raised position to the lowered position, placing the clean-out tool in its flow- through mode.

14. A method of cleaning out a wellbore using a clean-out tool, the wellbore having been lined with a string of production casing along a selected subsurface formation, and the method comprising: running a clean-out tool into the wellbore on a lower end of a string of coiled tubing, the clean-out tool comprising: a tubular housing providing an elongated bore through which fluids are injected, the tubular housing having one or more back jetting ports; a piston disposed at an upstream end of the tubular housing, the piston forming a pressure shoulder and having an orifice configured to deliver clean- out fluid from the coiled tubing string to the elongated bore of the housing; a tubular mandrel slidably positioned within the housing, the mandrel having a proximal end connected to or acted upon by the piston, and an open distal end forming a plunger; one or more radial slots disposed along the plunger; and a seat disposed along the tubular housing below the distal end of the tubular mandrel, the seat being dimensioned to slidably receive the plunger when the piston and connected tubular mandrel slide from a raised position providing a back-jetting mode wherein the radial slots are above the seat, to a lowered position providing a flow-through mode wherein the radial slots are along or below the seat; locating the clean-out tool at a selected depth along the wellbore; pumping clean-out fluid down the coiled tubing and into the bore of the tubular housing at a first flow rate, thereby causing at least a portion of the clean-out fluid to flow through the mandrel, up a lower annular region and through the back jetting ports while a remaining portion flows through a distal end of the tubular housing; and further pumping the clean-out fluid down the coiled tubing and into the bore of the tubular housing at a second flow rate that is higher than the first flow rate, thereby increasing a hydraulic force acting on the pressure shoulder of the piston and causing the mandrel and connected plunger to slide along the tubular housing such that the plunger advances through the seat, thereby forcing all of the injected clean-out fluid to flow through the distal end of the tubular housing.

15. The method of claim 14, wherein: the at least one radial slot comprises a plurality of radially-disposed slots; the plunger is configured to move in telescopic relation to the seat in response to the changes in fluid flow rate; and in the raised position, the radial slots reside above the seat, while in the lowered position the radial slots reside along or below the seat.

16. The method of claim 15, wherein the tubular housing comprises: an upper sub having a first upper end and a second lower end; and a lower sub having a first upper end proximate to the seat, and a lower end threadedly connected to a downhole tool.

17. The method of claim 16, wherein the downhole tool is (i) a hydraulic nozzle, (ii) a bridge plug, (iii) a sliding sleeve shifting tool, or (iv) a positive displacement motor.

18. The method of claim 15, wherein the clean-out tool further comprises: a lower annular region formed between the mandrel and the surrounding tubular housing providing fluid communication between the elongated bore of the tubular housing and the back jetting ports; the plunger defines a tubular body having an outer diameter; the through-opening of the seat comprises an inner diameter dimensioned to closely receive the outer diameter of the plunger; and at least a portion of the plunger overlaps the through-opening of the seat when the plunger is in its raised position.

19. The method of claim 18, wherein: the inner diameter of the plunger below the radial slots is tuned to adjust a flow split of clean-out fluid between the back jetting ports and the seat while the clean-out tool is in its raised position.

20. The method of claim 18, wherein: a lower end of the plunger is completely closed off to flow; and the radially-disposed slots reside above the lower end of the plunger such that all clean-out fluid flows back through the back jetting ports when the clean-out tool is in its back-jetting mode.

21. The method of claim 18, wherein: the wellbore comprises a string of production tubing, and running a clean-out tool into the wellbore comprises running the coiled tubing string and connected clean-out tool into the string of production tubing.

22. The method of claim 18, wherein the clean-out tool further comprises: a spring residing in an upper annular region between the tubular mandrel and the tubular housing above the lower annular region, the spring being pre-loaded in compression to bias the mandrel and connected plunger in the first raised position; and a sequencing mechanism comprising a cylindrical body, wherein the sequencing mechanism is responsive to a sequence of flow rates applied above the piston; and wherein at least one of the one or more back jetting ports is disposed along the tubular housing at an upward angle.

23. The method of claim 22, wherein the sequencing mechanism is configured to cycle the mandrel and connected plunger between: a raised position wherein the clean-out tool is in the back-jetting mode; an intermediate position wherein the clean-out tool remains in its back-jetting mode and the radial ports of the plunger remain above the seat even though flow rate is above an activation rate, and a lowered position wherein the clean-out tool is in the fluid flow-through mode.

24. The wellbore clean-out tool of claim 23, wherein: the sequencing mechanism is a J-slot sequencing mechanism; the J-slot sequencing mechanism cooperates with at least one pin disposed along the tubular housing configured to ride in slots along the cylindrical body to cycle the mandrel and connected plunger between the raised position, the intermediate position and the lowered position; and wherein the pin is fixed from axial movement and rides in the J-slots of the mandrel to restrict axial movement of the mandrel on alternating downward strokes.

25. The method of claim 24, wherein the J-slot mechanism and spring are configured to: (i) maintain the clean-out tool in its raised position while pumping at or below a first pump rate, placing the clean-out tool in the back-jetting mode wherein at least a portion of the clean-out fluid flows through the mandrel, up the lower annular region, and through the back jetting ports; (ii) maintain the clean-out tool in its intermediate position while increasing pump rate above the first pump rate, and wherein the same portion of the clean-out fluid flows through the mandrel, up the lower annular region and through the back jetting ports; (iii) upon dropping the pump rate back down to or below the first pump rate, maintaining the clean-out tool in its raised position; (iv) upon raising the pump rate to a rate that meets or exceeds a second pump rate, move the clean-out tool to its lowered position, placing the clean-out tool in its flow-through mode wherein all clean-out fluid is forced through the plunger below the seat and downstream of the clean-out tool; and (v) repeat the cycle of steps (i) through (iv).

26. The method of claim 25, wherein step (v) is done without reverse circulating in the wellbore.

27. The method of claim 24, wherein the J-slot mechanism and spring are configured to cycle between three settings, comprising: (i) a first setting wherein the pin resides in a first slot that places the mandrel and connected plunger in the raised position in response to the biasing mechanical force exerted by the spring on the mandrel while pumping at a first rate, placing the clean-out tool in its back-jetting mode; (ii) a second setting wherein the pin moves higher in the first slot in response to the pumping of the clean-out fluid into the coiled tubing at an increased pumping rate, so that the plunger advances to the intermediate position while remaining in its back-jetting mode; (iii) the first setting again wherein the pin resides in a second slot that allows the plunger to remain in the raised position; and (iv) a third setting wherein the pin moves higher in the second slot in response to the injection of the clean-out fluid into the coiled tubing at a second increased rate, or at any rate higher than the second rate, and wherein the plunger slides from the raised position to the lowered position, placing the clean-out tool in its flow-through mode.

28. The method of claim 27, further comprising: adjusting an aperture size of the orifice associated with the piston, thereby accommodating flow rate variations associated with the raised and lowered positions of the mandrel.

29. The method of claim 18, further comprising: selecting a cross-sectional area of the piston orifice, selecting a cross-sectional area of the one or more back jetting ports; selecting a cross-sectional area of the radial slots in the plunger; selecting a cross-sectional area of the plunger below the radial slots of the plunger; selecting a cross-sectional area of the lower annular region; or combinations thereof, before running the clean-out tool into the wellbore.

30. The method of claim 29, further comprising: monitoring a pressure of the clean-out fluid from the surface as it is injected into the tubular housing; and receiving confirmation that the clean-out tool has entered its flow-through mode when pressure reaches a designated level.

31. A method of cleaning out a wellbore using a clean-out tool, comprising: (a) placing a clean-out tool in the wellbore along a string of production casing, the clean-out tool comprising: a tubular housing providing an elongated bore through which fluids may flow, the tubular housing having one or more back jetting ports disposed at an upward angle therein; a piston disposed at an upstream end of the housing, the piston forming a pressure shoulder and having an orifice configured to deliver fluids from a conveyance string in the wellbore to the elongated bore of the housing; a tubular mandrel slidably positioned within the housing, the mandrel having a proximal end connected to or acted upon by the piston, and an open distal end forming a plunger; one or more radial slots disposed along the plunger; a seat disposed along the tubular housing below the distal end of the tubular mandrel, the seat being dimensioned to slidably receive the plunger when the piston and connected mandrel slide from a raised position providing a back-jetting mode wherein the radial slots are above the seat to a lowered position a providing a flow-through mode wherein the radial slots are along or below the seat; and a lower sub having a first upper end proximate to the seat, and a lower end threadedly connected to a downhole tool such that the clean-out tool and the downhole tool together form a bottom hole assembly (BHA); (b) locating the BHA within the wellbore; (c) pumping the clean-out fluid down the wellbore and into the clean-out tool at or above an activation rate, causing the tubular mandrel and connected plunger to move to its lowered position; (d) continuing to pump the clean-out fluid down the wellbore and into the clean-out tool at a rate above the activation rate in order to initiate operation of the downhole tool; and (e) pumping the clean-out fluid down the wellbore and into the clean-out tool at a rate below the activation rate, causing the tubular mandrel and connected plunger to move to the raised position so that at least a portion of the clean-out fluid flows through the back jetting ports, while also discontinuing operation of the downhole tool.

32. The method of claim 31, wherein the clean-out tool further comprises: a lower annular region formed between the mandrel and the surrounding tubular housing providing fluid communication between the elongated bore of the tubular housing and the back jetting ports; a J-slot mechanism responsive to the fluid flow rates and configured to cycle between the back-jetting mode and the flow-through mode.

33. The method of claim 32, wherein: the plunger defines a tubular body having an outer diameter; the seat comprises a through-opening dimensioned to closely and telescopically receive the outer diameter of plunger; the one or more radial slots comprise a plurality of radially-disposed slots above a lower end of the plunger, providing fluid communication between the bore and the lower annular region; the lower end of the plunger slidably overlaps with the through-opening of the seat when the piston and connected mandrel are in the raised position; in the raised position, radial slots of the plunger reside above the seat; and in the lowered position, the radial slots of the plunger reside along or below the seat.

34. The method of claim 33, wherein: the downhole tool is a milling tool or comprises a drill bit; and operating the downhole tool comprises (i) milling a plug within the wellbore, (ii) milling out debris along the wellbore, or (iii) drilling a formation to extend the wellbore.

35. The method of claim 33, further comprising: lightening a hydrostatic head formed by the clean-out fluid during the back-jetting mode.

36. The method of claim 33, wherein: a setting tool resides within the wellbore downstream from the downhole tool; and the method comprises cleaning out the wellbore while the clean-out tool is in its back-jetting mode without activating the setting tool.

37. The method of claim 33, wherein: a bridge plug resides within the wellbore downstream from the downhole tool; and the method comprises: cleaning out the wellbore while the clean-out tool is in its back-jetting mode and while the resettable bridge plug is not set; placing the clean-out tool in its flow-through mode; and cleaning out the wellbore while the clean-out tool is in its flow-through mode while the bridge plug is set.

38. The method of claim 32, wherein: the downhole tool is a hydraulic nozzle; and operating the downhole tool comprises injecting acid into the clean-out tool as the clean-out fluid.

39. The method of claim 32, wherein: the downhole tool is a sliding sleeve shifting tool; and operating the downhole tool comprises: cleaning out the wellbore while the clean-out tool is in its back-jetting mode and without activating the sliding sleeve shifting tool; placing the clean-out tool in its flow-through mode; and shifting a sliding sleeve associated with the sliding sleeve shifting tool in the wellbore while the clean-out tool is in its flow-through mode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) So that the manner in which the present inventions can be better understood, certain illustrations, charts and/or flow charts are appended hereto. It is to be noted, however, that the drawings illustrate only selected embodiments of the inventions and are therefore not to be considered limiting of scope, for the inventions may admit to other equally effective embodiments and applications.

(2) FIG. 1A is a cross-sectional view of a clean-out tool (or flow diverter) of the present invention, in one embodiment. In this view, the clean-out tool is in its run-in position. During the injection of a clean-out fluid, a significant portion of the injected fluid flows to back jetting ports, while the remainder of the fluid flows through the end of the tool.

(3) FIG. 1B is a second cross-sectional view of the clean-out tool of FIG. 1A. Here, the clean-out tool has been cycled to an intermediate position. In this position, a significant portion of the injected fluid continues to flow to the back jetting ports while the remainder of the fluid flows through the end of the tool.

(4) FIG. 1C is a third cross-sectional view of the clean-out tool of FIG. 1A. Here, the tool has been cycled to its fully lowered position. In this position, a plunger has landed on a seat, and all of the injected fluid travels through the clean-out tool with virtually no clean-out fluid being diverted to the back jetting ports.

(5) FIG. 2A is a cross-sectional view of a clean-out tool of the present invention, in a second embodiment. In this view, the clean-out tool is again in its run-in position wherein a significant portion of injected clean-out fluid flows to back jetting ports, while a remaining portion flows through the end of the tool. In this embodiment, a more restricted orifice (or central flow-through opening) is used in the seat.

(6) FIG. 2B is a second cross-sectional view of the flow diverter of FIG. 2A. Here, the flow diverter has been cycled to an intermediate position. In this position, a significant portion of the injected fluid continues to flow to the back jetting ports while the remainder of the fluid flows through the end of the tool.

(7) FIG. 2C is a third cross-sectional view of the flow diverter of FIG. 2A. Here, the tool has been cycled to its lowered position. In this position, the plunger has landed on the seat, with virtually no clean-out fluid being diverted to the back jetting ports.

(8) FIG. 3A is a perspective view of a positive displacement motor as may be placed below the clean-out tool of either FIG. 1A or FIG. 2A.

(9) FIG. 3B is an example of a suitable sliding sleeve shifting tool that may be used as part of a bottom hole assembly with the flow diverter of FIG. 2A.

(10) FIG. 3C is an example of a bridge plug that may be set, retrieved or drilled out using a bottom hole assembly that includes the flow diverter of FIG. 2A.

(11) FIG. 3D is a cut-away view of an illustrative hydraulic jetting nozzle.

(12) FIG. 3E is a perspective view of an illustrative setting tool.

(13) FIG. 3F is a perspective view of a milling tool.

(14) FIG. 3G is a perspective view of a drill bit.

(15) FIG. 4A is a side view of a j-slot mechanism. In this view, pins are in a default position along the slots.

(16) FIG. 4B is another side view of the j-slot mechanism of FIG. 4A. In this view, the pins have advanced along the channel and are in an intermediate position.

(17) FIG. 4C is another side view of the j-slot mechanism of FIG. 4A. In this view, the pins have advanced along the channel to a second slot but have returned to the default position of FIG. 4A.

(18) FIG. 4D is still another side view of the j-slot mechanism of FIG. 4A. In this view, the pins have advanced to a new slot along the channel and are now in a fully raised position. In this position, the piston and connected mandrel have moved the plunger of the clean-out tool to its lowered position such that the plunger will land on the seat per FIG. 1C or FIG. 2C.

(19) FIG. 5A is side view of the mandrel of FIGS. 1A and 2A. So called J-slots are visible along the outer diameter of the mandrel. These are part of the sequencing mechanism.

(20) FIG. 5B is a cross-sectional view of the mandrel of FIG. 5A. The view of the J-slots is retained in phantom.

(21) FIG. 6A is cross-sectional view of a J-slot collar. The J-slot collar includes a pair of opposing pins that ride in the J-slots of FIG. 5A. The J-slot collar is also part of the sequencing mechanism.

(22) FIG. 6B is a perspective view of the J-slot collar of FIG. 6A.

(23) FIG. 7 is a cross-sectional view the back jet housing of FIGS. 1A and 2A. Back jetting ports are visible in the body of the housing.

(24) FIG. 8A is a side view of the piston assembly of FIGS. 1A and 2A.

(25) FIG. 8B is a cross-sectional view of the piston assembly of FIG. 8A.

(26) FIG. 8C is a perspective view of the piston assembly of FIG. 8A.

(27) FIG. 9A is a side view of the plunger of FIGS. 1A and 2A.

(28) FIG. 9B is a cross-sectional view of the plunger of FIG. 9A.

(29) FIG. 9C is a perspective view of the plunger of FIG. 9A.

(30) FIG. 10A is a side view of the stem of FIGS. 1A, 1B and 1C.

(31) FIG. 10B is cross-sectional view of the stem of FIG. 10A.

(32) FIG. 10C is a perspective view of the stem of FIG. 10A, taken from the distal end.

(33) FIG. 11A is a side view of the of the combined stem and seat of FIGS. 1A, 1B and 1C.

(34) FIG. 11B is a cross-sectional view of the combined stem and seat of FIG. 11A.

(35) FIG. 12A is a cross-sectional view of a clean-out tool of the present invention, in a third embodiment. In this view, the clean-out tool (or flow diverter) is again in its run-in position wherein a significant portion of injected clean-out fluid flows to back jetting ports, while a remaining portion flows through the end of the tool. In this embodiment, no stem is provided with the seat.

(36) FIG. 12A-P1 is an enlarged cross-sectional view of portion P1 of FIG. 12A. The relationship between the plunger and seat is more clearly seen.

(37) FIG. 12B is a cross-sectional view of the clean-out tool of FIG. 12A. Here, the clean-out tool has been cycled to an intermediate position. In this position, a significant portion of the injected fluid continues to flow to the back jetting ports while the remainder of the fluid flows through the end of the tool.

(38) FIG. 12B-P2 is an enlarged cross-sectional view of portion P2 of FIG. 12B. Here, it can be seen that the plunger has approached the seat.

(39) FIG. 12C is a third cross-sectional view of the clean-out tool of FIG. 12A. Here, the tool has been cycled to its lowered position. In this position, radial slots along the plunger have passed through the seat, causing virtually all clean-out fluid to flow through the seat and through the bottom of the clean-out tool.

(40) FIG. 12C-P3 is an enlarged cross-sectional view of portion P3 of FIG. 12B. Here, it can be seen that the plunger has passed across the seat.

(41) FIG. 12-P4 is another enlarged cross-sectional view of portion P1 of FIG. 12A. The radial slots once again are positioned above the seat. However, in this arrangement a lower portion of the plunger has a restricted flow-through channel.

(42) FIG. 12-P5 is still another enlarged cross-sectional view of portion P1 of FIG. 12A. The radial slots once again are positioned above the seat. However, in this arrangement a lower portion of the plunger has a closed off bottom.

(43) FIG. 13 is a cross-sectional view of a wellbore. Here, the wellbore has received the clean-out tool of FIG. 1A.

(44) FIG. 14 is a flow chart showing operational steps for controlling a flow of fluid through the clean-out tool, in one arrangement.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

(45) Definitions

(46) For purposes of the present application, it will be understood that the term hydrocarbon refers to an organic compound that includes primarily, if not exclusively, the elements hydrogen and carbon. Hydrocarbons may also include other elements, such as, but not limited to, halogens, metallic elements, nitrogen, carbon dioxide, and/or sulfuric components such as hydrogen sulfide.

(47) As used herein, the term hydrocarbon fluids refers to a hydrocarbon or mixtures of hydrocarbons that are gases or liquids. For example, hydrocarbon fluids may include a hydrocarbon or mixtures of hydrocarbons that are gases or liquids at formation conditions, at processing conditions, or at ambient condition.

(48) As used herein, the terms produced fluids, reservoir fluids and production fluids refer to liquids and/or gases removed from a subsurface formation, including, for example, an organic-rich rock formation. Produced fluids may include both hydrocarbon fluids and non-hydrocarbon fluids. Production fluids may include, but are not limited to, oil, natural gas, pyrolyzed shale oil, synthesis gas, a pyrolysis product of coal, nitrogen, carbon dioxide, hydrogen sulfide and water.

(49) As used herein, the term fluid refers to gases, liquids, and combinations of gases and liquids, as well as to combinations of gases and fines, combinations of liquids and fines, and combinations of gases, liquids, and fines.

(50) As used herein, the term wellbore fluids means water, hydrocarbon fluids, formation fluids, or any other fluids that may be within a wellbore during a production operation.

(51) As used herein, the term subsurface refers to geologic strata occurring below the earth's surface.

(52) As used herein, the term formation refers to any definable subsurface region regardless of size. The formation may contain one or more hydrocarbon-containing layers, one or more non-hydrocarbon containing layers, an overburden, and/or an underburden of any geologic formation. A formation can refer to a single set of related geologic strata of a specific rock type, or to a set of geologic strata of different rock types that contribute to or are encountered in, for example, without limitation, (i) the creation, generation and/or entrapment of hydrocarbons or minerals, and (ii) the execution of processes used to extract hydrocarbons or minerals from the subsurface region.

(53) As used herein, the term wellbore refers to a hole in the subsurface made by drilling or insertion of a conduit into the subsurface. The term well, when referring to an opening in the formation, may be used interchangeably with the term wellbore.

Description of Selected Specific Embodiments

(54) FIG. 1A is a cross-sectional view of a clean-out tool (or flow diverter) 100 of the present invention, in one embodiment. The clean-out tool 100 is used to inject fluids into a wellbore for clean-out. An illustrative wellbore is shown at 1300 in FIG. 13 and is discussed below.

(55) The clean-out tool 100 defines a generally tubular body formed from a series of components. As shown, the clean-out tool 100 has a first (or upstream) end 102 and a second (or downstream) end 104. A central bore 105 is formed within the body extending from the first end 102 to the second end 104.

(56) As will be discussed, the clean-out tool 100 is configured to cycle a position of a mandrel 155 and connected plunger 160 in response to fluid pumping rates into the wellbore 1200 by an operator. In this way, a flow of clean-out fluid through the tool 100 may be adjusted. In the view of FIG. 1A, the clean-out tool 100 is in its run-in position wherein a portion of the injected fluid flows through the tool 100 from the top (or upstream) end 102 to the bottom (or downstream) end 104 en route to a next downhole tool or to the bottom of the wellbore 1300, as the case may be. At the same time, at least some of the injected fluid will exit a back jet housing 140 and exit the clean-out tool 100 through radial back jetting ports 148.

(57) The clean-out tool 100 first includes a top sub 110. The top sub 110 defines a tubular body wherein a first (or upstream) end 112 comprises female threads while a second (or downstream) end 114 comprises male threads. The female threads are configured to threadedly connect to a bottom hole assembly (or BHA) above (not shown). The upper BHA, in turn, is connected to a string of coiled tubing or other working string, such as through a CT connector (not shown).

(58) The clean-out tool 100 next includes a spring housing 120. The spring housing 120 also defines a generally tubular body wherein a first (or upstream) end 122 comprises female threads while a second opposite end 124 comprises male threads. The first end 122 of the spring housing 120 threadedly connects to the second (or downstream) end 114 of the top sub 110.

(59) The clean-out tool 100 also includes a spring 125. The spring 125 resides along an inner diameter of the spring housing 120. The spring 125 is held in compression within the tool 100. In one aspect, the spring 125 is an Inconel spring. Alternatively, the spring material is 17-7 stainless steel. Of interest, a shoulder 126 resides along an inner diameter of the spring housing 120. The shoulder 126 serves as a face against which the spring 125 resides.

(60) Moving down the tool 100, the clean-out tool 100 next includes a mandrel seal sub 130. The mandrel seal sub 130 also defines a generally tubular body wherein a first (or upstream) end 132 comprises female threads while a second opposite (or downstream) end 134 comprises male threads. The upstream end 132 threadedly connects to the second (or downstream) end 124 of the spring housing 120. Of interest, the mandrel seal sub 130 encompasses a portion of a sequencing mechanism 400, discussed below.

(61) The clean-out tool 100 also comprises a back jet housing 140. The back jet housing 140 also defines a generally tubular body wherein a first (or upstream) end 142 comprises female threads while a second (or downstream) opposite end 144 also comprises female threads. The back jet housing 140 resides downstream from the top sub 110 and the spring housing 120. The first end 142 of the back jet housing 140 threadedly connects to the second end 134 of the mandrel seal sub 130.

(62) Of importance, the back jet housing 140 comprises one or more back jetting ports 148. The back jetting ports 148 are placed within the back jet housing 140 at an upward angle. Preferably, the angle is between 10 and 60, and more preferably at about 45 from the central longitudinal axis. The back jetting ports 148 may be also be disposed radially about the back jet housing 140, such as at 15 radially. Preferably, a plurality of back jetting ports 148 are placed radially around the back jet housing 140 along at least two levels, and optionally at different angles.

(63) The top sub 110, the spring housing 120, the mandrel seal sub 130, the back jet housing 140 and the lower sub 190 together make up a tubular housing for the clean-out tool 100. Of interest, a shoulder 146 resides along an inner diameter of the back jet housing 140. The shoulder 146 forms a profile above the back jetting ports 148. A separate shoulder 136 resides at the bottom end 134 of the mandrel seal sub 130. O-rings are placed inside the bottom end 134, helping to keep clean-out fluid from flowing from the annular area between the mandrel 155 and the spring housing 120 and to the ports 148 during the flow-through mode.

(64) The clean-out tool 100 additionally includes a piston assembly 150. The piston assembly 150 defines a series of components that are configured to slide together along the spring housing 120 in response to fluid pressure. The piston assembly 150 includes an orifice retainer 151, a piston body 156, a piston orifice 153 and a piston scraper retainer 157. The piston assembly 150 essentially serves as a pressure shoulder, moving down the spring housing 120 in response to fluid pressure applied from the surface.

(65) It is observed here that while it is pressure that moves the piston assembly 150 down, it is also accurate to refer to changes in flow rate that actuate the piston assembly 150. This is because the piston orifice 153 is configured according to a desired flow rate to cause the tool 100 to change between modes. In this respect, the orifice 153 is sized to generate the required differential pressure across itself to function. External pressures do not have an impact on the piston assembly 150; only pressure from the flow rate through the orifice 153 changes the tool mode.

(66) The orifice retainer 151 secures the piston assembly 150 in place below the top sub 110. The orifice retainer 151 abuts the lower end 114 of the top sub 110 to hold the piston assembly 150 in place. Various o-rings (not numbered) may be disposed around the piston body 156 and the piston orifice 153 to prevent pressure communication between the areas above and below the piston assembly 150. Additional details concerning the piston assembly 150 are provided below in connection with FIGS. 8A through 8C.

(67) As stated above, the piston assembly 150 is operatively connected to a mandrel 155. The mandrel 155 has an upper (or upstream) end 152 connected to the piston assembly 150, and a lower (or downstream) end 154. The upper end 152 of the mandrel 155 is threadedly connected to the piston body 156. The piston assembly 150 and connected mandrel 155 reside within the inner diameter of the spring housing 120.

(68) In operation, hydraulic pressure (generated by fluid flow through the piston orifice 153) acts on the shoulder that is the upper side of the piston assembly 150 above the piston orifice 153. In response, the piston assembly 150 and connected mandrel 155 move down the tubular housing together. Specifically, the piston assembly 150 (and connected mandrel 155) moves from its raised position (shown in FIG. 1A), to an intermediate position (shown in FIG. 1B) and then to a lowered position (shown in FIG. 1C).

(69) An annular area 145 is reserved between the mandrel 155 and the surrounding back jet housing 140. The annular area 145 has an upper portion where the spring 125 resides, and a lower portion where back jetting ports 148 are placed. Appropriate o-rings reside around and inside the downstream end 134 of the mandrel seal sub 130 to provide a fluid seal between the upper and lower annular regions 145. The annular region the spring 125 resides in is pressure balanced via ports 129 in the mandrel 155. These ports 129 let the fluid volume inside the spring housing 120 change as the piston body 156 moves up and down.

(70) It is observed that the back jet housing 140 has an enlarged inner diameter portion 147. This has the effect of increasing the cross-sectional area of the lower portion of the annular region 145. The larger cross-sectional area of the enlarged inner diameter portion 147 enables a free flow of clean-out fluid en route to the ports 148. Clean-out fluid is used to clean the wellbore within the casing, preferably at the conclusion of or in conjunction with a completion operation. Alternatively, clean-out fluid may be used to clean production tubing following a period of production or other wellbore operation.

(71) At the lower end 154 of the mandrel 155 is a plunger 160. The plunger 160 defines a short tubular body having an upper (or upstream) end 162 and an opposing lower (or downstream) end 164. A bore 165 is formed from the upper 162 to the lower 164 end, allowing the clean-out fluid to flow through the plunger 160. The upper end 162 comprises male threads that connect to the lower end 154 of the mandrel 155. In this way, the plunger 160 moves up and down along the bore 105 of the clean-out tool 100 with the mandrel 155.

(72) As a next component, the clean-out tool 100 includes a lower sub 190. The lower sub 190 defines an elongated tubular body having an upper end 192 and a lower end 194. The upper end 192 comprises male threads that connect to the bottom end of the back jet housing 140. The lower sub 190 forms a bore 195 that is in fluid communication with and forms a part of the bore 105.

(73) Finally, the clean-out tool 100 comprises a seat 170. The seat 170 shown in FIG. 1A is a standard seat having a flow-through orifice 175 (shown in FIG. 11B). The seat 170 is configured to receive the lower end 164 of the plunger 160 when the piston body 150 is moved to a lowered position (seen in FIG. 1C). Specifically, the lower end 164 of the plunger 160 lands on a high-density, elastomeric annular seal 171 residing within the seat 170. The orifice 175 is sized to provide little to no restriction in downhole fluid flow.

(74) In a preferred embodiment, the orifice 175 of the seat 170 receives a stem 180. The stem 180 defines an elongated tubular body. The stem 180 has a proximal (or upper) end 182 (shown in FIGS. 10A and 10B) and a distal (or downstream) end 184. A bore 185 extends from the proximal end 182 to the distal end 184. Flow-through slots 181 are provided along the stem 180. Preferably, four equi-radially disposed slots 181 are provided. Additional details concerning the stem 180 are provided and discussed below in connection with FIGS. 10A-10C.

(75) In the view of FIG. 1A, the piston body 150 is at is uppermost position. This is its default (or raised) position wherein the orifice retainer 151 is abutting the lower end 114 of the top sub 110. The piston body 150 is held in this default position due to the upward mechanical force provided by the spring 125.

(76) As noted, a piston o-ring may be disposed around the piston body 156 to prevent pressure communication between the area above the piston body 156 and below the piston body 156 when fluid is passing through the orifice 153. Additionally, an orifice o-ring may be disposed around the orifice 153 to prevent pressure communication between the area above the orifice 153 and below the orifice 153 when fluid is passing through the orifice 153. The aperture size of the orifice 153 defines the activation rate. Thus, one aspect of using the multi-cycle wellbore clean-out tool 100 involves the selection of the aperture size of the piston orifice 153.

(77) In the raised position of FIG. 1A, fluid is injected by an operator into the bore 105 of the clean-out tool 100 under a first pressure. The first pressure correlates to a first flow rate. Those of ordinary skill in the art will understand that there is a correlation between flow rate, tubular dimension and pressure. At the first flow rate, the hydraulic pressure acting on the piston assembly 150 is not great enough to cause the piston assembly 150 to compress the spring 125.

(78) In the position of FIG. 1A, the plunger 160 extends only partially over the stem 180. Specifically, the plunger 160 remains above the four radially-disposed slots 181. As clean-out fluid is injected into the wellbore 1200 at the first flow rate, fluid will pass through the bore 165 of the plunger 160. A portion of the injected fluid will travel through the slots 181, back up the annular region 145 and up to the back jetting ports 148. The remaining portion of the fluid will flow through the stem 180, below the seat 170 and optionally on to other tools downhole.

(79) In one optional embodiment of the invention, a back pressure valve (not shown) is placed below the lower sub 190. The back pressure valve can either be threaded to the distal end 194 of the lower sub 190 or it can be used as the lower sub 190 itself. The back pressure valve works on the principle of biasing force of a spring which blocks the flow of fluids through a passage. The pressure of the fluids above act on an area and against the spring. The user can adjust the force of the spring, which in turn will adjust the force it takes to open an area of flow to the tools below the sub 190.

(80) In the present application, a back pressure valve can be configured to divert all of the flow to the back jetting ports 148 up to a pre-determined pressure, set by the operator. For example, if the planned back jetting rate corresponds to a 200 psi pressure drop across the back jetting ports 148, the back pressure valve can be set to open at 300 psi. When the tool 100 is in its back-jetting mode, all of the flow will go to the ports 148. When the plunger 160 contacts the seat 170 for flow-through mode, the back pressure valve will be forced open at 300 psi and will provide a pressure indication. This is useful when the operator wants to pump a fluid that it does not want to go through the tools below when in back-jetting mode, such as an acid or nitrogen.

(81) In an alternate embodiment, and as discussed below in connection with FIGS. 12A through 12C, a stem is not used in the seat; instead, a plunger 1260 with radial slots 1281 is used within clean-out tool 1200. In this embodiment, the radial slots 1281 are disposed above the seat 1270 when the clean-out tool 1200 is in its initial or intermediate position, and then moves below the seat 1270 when the clean-out tool 1200 is in its lowered position. No through-bore is provided below the radial slots 1281. In this way, clean-out fluid communicates exclusively with either the back jetting housing 140 or to the tools below the seat 1270 separately.

(82) In another embodiment, a positive displacement motor is used below the lower sub 190, wherein the motor has a high off-bottom pressure. In this instance, virtually all of the injected fluid in the plunger's raised position will be diverted to the back jetting ports 148.

(83) For the embodiment of FIG. 1A, it is understood that the percentage of fluids flowing back through the ports 148 during the back-jetting mode is a function of various factors. These include the diameter of the ports 148, the number of the ports 148, the combined cross-sectional area of the flow through slots 181, and the cross-sectional area of the annular region 145. In addition, the total volume of fluid pumped through the clean-out tool 100 is a function of the inner diameter of the piston orifice 153 and the diameter of the bore 105. Therefore, as part of a method of cleaning out a wellbore herein, the operator determines the number of ports to be used, the size of the ports, the inner diameter of the piston orifice 153, the area of the slots 181, the diameter of the bore 155 and the size of the annular region 145 around the bore 155. These steps are indicated at Box 1460 of the flow chart of FIG. 14, discussed below.

(84) Once the wellbore clean-out tool 100 is run into the wellbore 1300, the operator will begin pumping. During pumping, the operator will increase the pump rate. This will apply a greater hydraulic force to the shoulder of the piston assembly 150 and will start to overcome the biasing force of the spring 125 (plus any friction created by o-rings). The piston assembly 150, the mandrel 155 and its connected plunger 160 will then start to move down the bore 105.

(85) FIG. 1B is a cross-sectional view of the clean-out tool 100 of FIG. 1A. Here, the clean-out tool 100 is translating (that is, sliding down the spring housing 120) to its intermediate position. This is done by increasing the hydraulic force acting on the piston assembly 150. The increased hydraulic force is achieved by increasing pump rate of the hydraulic fluid into the wellbore from the surface. In response to the increased pressure (or increasing pump rate), the piston body 150 and connected plunger 160 have slid down to a position where the lower end 164 of the plunger 160 approaches the radial slots 181 in the stem 180. However, it is important to note that in this intermediate position the radial slots 181 remain exposed to the lower annular region 147 and the tool 100 continues to operate in its back-jetting mode.

(86) FIG. 1C is a third cross-sectional view of the clean-out tool of FIG. 1A. Here, the clean-out tool 100 has been cycled to its lowered position. This is done by further increasing the pump rate above an activation rate, thereby increasing the hydraulic force acting on the shoulder that is the piston assembly 150. As the plunger 160 moves below the radial slots 181, substantially all of the clean-out fluid will flow down through the seat 170, into the bore 195 of the lower sub 190, and out of the tool 100.

(87) The cycling of the tool 100 between its raised position (FIG. 1A), its intermediate position (FIG. 1B) and its lowered position (FIG. 1C) is preferably accomplished by using a sequencing mechanism. The sequencing mechanism is preferably a J-slot mechanism as shown in FIGS. 4A-4D, discussed below. The sequencing mechanism 400 allows the operator to cycle the flow rates to move the tool 100 between settings so that: (i) in a first setting, the plunger 160 is in a raised position in response to the biasing mechanical force exerted by the spring 125 on the mandrel 155, placing the clean-out tool in a back-jetting mode; (ii) in a second setting, pumping rate is increased and the J-slot mechanism 400 advances to a next slot, allowing the plunger 160 to move down no more than to its intermediate position and allowing the operator to inject hydraulic fluid into the bore 105 of the tubular housing 110 and through the piston orifice 153 at a second rate, or at any rate higher than the second rate, and keeping the clean-out tool in its back-jetting mode; (iii) in the first setting again, hydraulic pumping rate is reduced to its first rate, or any rate below the first rate, and the clean-out tool 100 remains in its back-jetting mode; and (iv) in a third setting, the plunger 160 is forced down into a lowered position in response to the injection of hydraulic fluid through the piston assembly 150 and into the clean-out tool 100 at a second rate, or at any rate higher than the second rate, moving the J-slot mechanism 400 to a next slot and causing the plunger 160 to slide from the raised position to the lowered position, placing the clean-out tool 100 in its flow-through mode.

(88) It is observed in FIG. 1C that the piston body 150 has lowered the plunger 160 down to a position where the plunger 160 has landed onto the seat 170. In this position, all of the injected fluids travel through the lower end 184 of the stem 180 and to the bottom end 104 of the clean-out tool 100, with essentially no fluids being diverted to the back jetting ports 148.

(89) In the diverter tool 100 of FIGS. 1A-1C, the stem 180 is a standard-sized stem that simply receives the plunger 160 when the piston body 150 is urged down to its lowered position. The O.D. of the stem 180 is configured to slidably receive the lower end 164 of the plunger 160 until the plunger 160 passes below the slots 181 in the stem 180. This may be referred to as landing the plunger on the seat as the plunger 160 is contacting a seal which is considered as integral to the seat 170. No significant pressure drop takes place through the standard stem 180. However, the operator may believe that the standard stem 180 allows too much fluid to pass through the bottom end 104 of the clean-out tool 100, limiting the amount of pressure provided by fluids passing through the back jetting ports 148. In this instance, the operator may choose to use a restricted orifice seat. This is done by reducing the I.D. of the stem 180.

(90) FIG. 2A is a cross-sectional view of a clean-out tool 200 of the present invention, in a second embodiment. In this view, the clean-out tool 200 is again in its run-in position wherein a substantial portion of injected fluid flows to the back jetting ports 148, while the remaining fluid flows through the lower sub 190 of the tool 200 en route to a next downhole tool. The clean-out tool 200 is built in accordance with the clean-out tool 100 described above. However, in this design a restricted orifice stem 280 has been placed below the plunger 160 in lieu of the stem 180. The restricted orifice stem 280 has a more restrictive through opening 285, limiting the amount of working fluid that can pass through the stem 280.

(91) Beneficially, the stem 280 provides a better indicator at the surface as to the position of the plunger 160 (via pump pressure) during cycling. Also as noted, the use of the restricted-orifice stem 280 and its flow-through opening 285 directs a greater percentage of injected fluid to the back jetting ports 148. For example, in the embodiment of FIG. 2A the percentage of redirected fluid might be 30% to 40%, or 40% to 50%, or 50% to 90% of the injected fluid. This is true even where the components below the tool 100 have low back pressure.

(92) As with the clean-out tool 100 of FIG. 1A, the clean-out tool 200 of FIG. 2A is configured to move from its raised position (FIG. 2A) down to its lowered position (FIG. 2C). This again is done through the use of a cycling mechanism, such as the J-slot mechanism 400 shown in FIGS. 4A through 4D.

(93) FIG. 2B is a cross-sectional view of the clean-out tool 200 of FIG. 2A. Here, the clean-out tool 200 is translating from its raised position to its intermediate position. En route, a portion of the injected fluid will continue to be diverted through the radial slots 181 and on to the back jetting ports 148. As with the embodiment of FIG. 1B, a portion of the hydraulic fluid will flow back up the lower annular region 147, and then through the back jetting ports 148. The remaining portion of injected fluid will continue to flow down through the stem 280, into the bore 195 of the lower sub 190, and out of the tool 200. Because the orifice 285 is restricted, this will urge a greater portion of injected clean-out fluid to travel back to the back jetting ports 148.

(94) FIG. 2C is a third cross-sectional view of the flow diverter 200 of FIG. 2A. Here, the flow diverter 200 has been cycled to its fully lowered position. In this position, all of the injected fluid travels through the flow diverter 200, with substantially no clean-out fluid being diverted to the back jetting ports 148. This may be done by increasing hydraulic pressure within the bore 105 of the clean-out tool 200 from the first pressure to the second greater activation pressure. Hydraulic pressure again is increased by increasing pump rate from the surface.

(95) It is observed that in each of the views of FIGS. 1A-1C and 2A-2C, no tool is shown below the lower sub 190. However, the bottom end 194 of the sub 190 is configured to threadedly connect to a separate tool that may be placed in the wellbore 1300 below the clean-out tool 100 or 200. For example, a positive displacement motor (presented at 300A in FIG. 3A) may be placed downstream from the clean-out tool 200. In this instance, the restricted-orifice stem 280 replaces the standard-sized stem 180 to provide an improved feedback signal through pressure increase of approximately 200 psi (with 1.01 SG Fluid) at the same pump-rate to indicate the flow-through mode. Additionally, the restricted-orifice stem 280 provides a secondary function of limiting the flow to the motor 300A while in back-jetting mode.

(96) FIG. 3A is a perspective view of a positive displacement motor 300A. This provides an example of a tool that may be connected to the lower sub 190 or otherwise placed below the lower sub 190 as part of a tool string. The positive displacement motor 300A may be placed below the clean-out of either FIG. 1A or FIG. 2A. Preferably, the positive displacement motor 300A would be used in connection with the embodiment 200 of FIGS. 2A-2C. It is understood that the positive displacement motor 300A is merely illustrative; other positive pressure tools may be placed downstream of the seat 170.

(97) It can be seen that the motor 300A includes an elongated tubular body 310. The body 310 defines a fluid in-take end 312 and a fluid outlet end 314. The positive displacement motor 300A operates with a rotor and a stator residing within the tubular body 310. In one aspect, the positive displacement motor 300A is used as an agitator, sending pressure pulses across the wellbore downhole while cleaning. In another aspect, a small drill bit (such as shown in FIG. 3G) is connected to the outlet end 314, and is turned by the rotor of the motor 300A. The drill bit 300G may also be used for clean-out.

(98) In any instance, the use of the restricted-orifice stem 280 is particularly appropriate if the off-bottom pressure of the positive displacement motor 300A is low. However, depending upon the characteristics of the positive displacement motor 300A, the larger orifice 185 provided in the standard stem 180 may also be acceptable to use.

(99) As an alternative to the motor 300A of FIG. 3A, a separate hydraulic nozzle may be placed below the lower sub 190. An illustrative nozzle 300D is shown in FIG. 3D. In this instance, a standard stem 180 would be used. The separate nozzle 300D is preferably the Helix nozzle provided by Coil Solutions Inc. of Calgary, Alberta. The nozzle would be used for wellbore clean-out below the tool 100. In an alternative embodiment, and a described further below, a sliding sleeve shifting tool is placed below the lower sub 190.

(100) FIG. 3D is cut-away view of an illustrative nozzle 300D as may be placed below the wellbore clean-out tool 100. The illustrative nozzle is manufactured by National Oilwell Varco, or NOV, based in Houston, Texas.

(101) In order to move the clean-out tool 100 or 200 through its position cycles, the operator may increase pressures incrementally. Based upon piston orifice 153 I.D., stem 180 or 280 I.D. and total back jetting port 148 through-opening area, the operator will know at what rate to pump for each cycle. For example, the operator will know a second rate to pump that places the plunger 160 at its lowest, or seated position (FIGS. 1C and 2C). The difference in tubular pressure between the two modes at the same pump rate serves as a position indicator for cycling.

(102) To enhance the cycling, a sequencing mechanism such as a J-slot mechanism may be provided. A J-slot mechanism is a cylindrical device having a circuitous channel forming slots. One or more pins ride along the slots, rotating from slot-to-slot in response to changes in fluid pressure.

(103) FIG. 4A is a side view of a portion of a J-slot mechanism 400. It can be seen that a pair of pins 482 reside in respective lower slots 484A. This is a slot position that would correlate with the default, or raised position of the plunger 160 as presented in FIGS. 1A and 2A. In this position, the pump rate is below the activation rate. This cycle position will allow injected fluid to flow to the back jet housing 140 while sending the remaining portion of the fluid on through the bottom end 194 of the lower sub 190.

(104) FIG. 4B is another side view of the J-slot mechanism 400 of FIG. 4A. In this view, the pins 482 have advanced one slot 484B. In slot 484B, the pins 482 are in an intermediate position. This is a slot position that would correlate to the operator increasing pump rate from the surface as shown in FIGS. 1B and 2B. In this position, the location of the J-slot pins 482 restricts the movement of the plunger 160 while allowing the flow-rate to beneficially move above the activation rate. In other words, the plunger 160 will not advance along the stem 180 even when the pump rate is well above the activation rate, allowing vigorous back jetting through ports 148.

(105) FIG. 4C is another side view of the J-slot mechanism 400 of FIG. 4A. In this view, pumping rate has been dropped back below the activation rate, causing the pins 482 to follow along the channel and to advanced one slot 484A. In this position 484A, the plunger 160 has returned to its raised position per FIGS. 1A and 2A.

(106) FIG. 4D is still another side view of the J-slot mechanism 400 of FIG. 4A. In this view, the pump rate has again been increased above the activation rate, causing the pins 482 to advance along the channel to a next slot 484D. In this position, the plunger 160 is seated, isolating the back jetting ports 148 from fluid injection per FIGS. 1C and 2C. In this position, the operator may inject at high rates to operate a motor 300A or to direct all fluids through a downhole jetting nozzle (not shown). Once the plunger 160 has landed, increases in pump rate will not move the pins 482 any higher in slots 484D.

(107) The pins 482 advance from slot-to-slot in response to alternating cycles of the piston body 150 and connected internals moving longitudinally. The pins 482 cause the piston assembly 150 and connected internals to ratchet, or rotate, in a circular path. Also, the component housing the J-slot pin or pins 482 may ratchet, or rotate, in a circular path. The J-slot grooves (484A, 484B, 484D) are configured so that the piston body 150 and connected internals travel is unrestricted in the upward direction so that every time the flow rate is brought below the activation rate the plunger 160 is in its raised position and cannot seal against the seat 170 or 270. Additionally, on alternating cycles of the flow rate being brought to or above the activation rate, the J-slot grooves (484A, 484B, 484D) restrict the travel of the piston body 150 and connected internals so the plunger 160 cannot seal against the seat 170 or 270.

(108) Beneficially, the annular area 145 communicating to the back jetting ports 148 remains open for clean-out at rates above the activation rate. On opposite alternating cycles of the flow rate being brought to or above the activation rate, the J-slot grooves (484D) allow the piston body 150 and connected internals to travel further down so that the plunger 160 passes across the radial slots 181 of the stem 280 (FIG. 2B) and then the plunger 160 contacts the seat 270 (FIG. 2C), enabling full flow-through to any tools (such as motor 300A) disposed below the clean-out tool 200.

(109) FIG. 5A is side view of the mandrel 155 of FIGS. 1A and 2A. So called J-slots 410 are visible along the outer diameter of the mandrel 155.

(110) FIG. 5B is a cross-sectional view of the mandrel 155 of FIG. 5A. In both FIGS. 5A and 5B, slot 484D of the J-slots 410 is visible. Here, the J-slots 410 are shown in phantom.

(111) It is understood that the J-slots 410 of FIGS. 5A and 5B are part of the sequencing mechanism 400. The J-slots 410 work in tandem with a J-slot collar (shown at 420 in FIG. 6A).

(112) FIG. 6A is cross-sectional view of a J-slot collar 420. The J-slot collar 420 includes a pair of opposing pins 482 that ride in the J-slots 410 of FIG. 5A.

(113) FIG. 6B is a perspective view of the J-slot collar 420 of FIG. 6A. Visible in this view is one of the pins 482 extending inwardly into a bore 425.

(114) FIG. 7 is a cross-sectional view of the back jet housing 140 of FIGS. 1A and 2A. The proximal (or upstream) end 142 and the distal (or downstream) end 144 are visible. It is observed that the back jet housing 140 defines a wall 141 forming a bore 145. The bore 145 extends from the proximal 142 to the and distal 144 end. The back jetting ports 148 are visible in the wall 141 making up the housing 140.

(115) FIG. 8A is a side view of the piston assembly 150 of FIGS. 1A and 2A.

(116) FIG. 8B is a cross-sectional view of the piston assembly 150 of FIG. 8A.

(117) FIG. 8C is a perspective view of the piston assembly 150 of FIG. 8A. The piston assembly 150 will be discussed with reference to FIGS. 8A-8C together.

(118) The piston assembly 150 includes an orifice retainer 151, a piston body 156, a piston orifice 153 and a piston scraper retainer 157. The piston orifice 153 resides below the orifice retainer 151. The piston orifice 153 comprises a shoulder, with the shoulder being exposed to fluid pressure above the fluid assembly 150. The piston orifice 153 includes a central through-opening that permits working fluids to flow through the piston assembly 150 during clean-out operations. Piston scrapers (not shown) may be disposed around the piston body 156 to ensure debris is not able to reach the piston body o-ring.

(119) FIG. 9A is a side view of the plunger 160 of FIGS. 1A and 2A.

(120) FIG. 9B is a cross-sectional view of the plunger 160 of FIG. 9A.

(121) FIG. 9C is a perspective view of the plunger of FIG. 9A, taken from a distal end. The plunger 160 will be discussed with reference to FIGS. 9A-9C together.

(122) As noted above, the plunger 160 has an upper end 162, a lower end 164 and a bore 165 formed there between. The bore 165 has an inner diameter (ID). The ID is dimensioned to slidingly receive the stem 180 when moving between its back-jetting mode and its flow-through mode. The plunger 160 is made up of a wall 161 that forms the bore 165.

(123) FIG. 10A is a side view of the stem 180 of FIGS. 1A, 1B and 1C.

(124) FIG. 10B is cross-sectional view of the stem 180 of FIG. 10A.

(125) FIG. 10C is a perspective view of the stem 180 of FIG. 10A, taken from the distal end. The stem 180 will be discussed with reference to FIGS. 10A, 10B and 10C together.

(126) The stem 180 defines an elongated tubular body. The stem 180 has a proximal (or upper) end 182 and a distal (or downstream) end 184. A bore 185 extends from the proximal end 182 to the distal end 184. Through-openings (or slots) 181 are provided along the stem 180. In the arrangement of FIGS. 10A-10C, four equi-radially disposed slots 181 are provided.

(127) The proximal end 182 of the stem 180 has an outer diameter OD. The OD is dimensioned to be slidably received within the ID of the plunger 160. When the piston assembly 150 and connected plunger 160 are in their raised or intermediate position (or back-jetting mode), the bottom of the plunger 160 resides above the slots 181. In this position, jetting fluids are split, with a portion of fluids flowing through the through-openings 181 and back up to the back jetting ports 148, and a portion flowing on down through the bore 185 of the stem 180.

(128) When the piston assembly 150 and connected plunger 160 are in their lowered (or flow through) mode, the bottom of the plunger 160 advances past the slots 181. In this position, most (and preferably all) of the jetting fluids flow down through the bore 185 of the stem 180 and to a tool below. In either the back-jetting mode or the flow-through mode the plunger 160 is disposed over the OD of the stem 180. In other words, the stem 180 is always overlapping the plunger 160 to at least some extent. In one embodiment, when the piston assembly 150 and connected mandrel 155 are in their upper position, the plunger 160 will overlap with the stem 180 by about .

(129) In the arrangement shown in FIGS. 1A-1C and 2A-2C, the stem 180, 280 is received within the plunger 160. However, the alternate telescopic relationship may also be employed, that is, the plunger 160 is received within the stem 180.

(130) FIG. 11A is a side view of the combined seat 170 and stem 180 of FIGS. 1A, 1B and 1C.

(131) FIG. 11B is a cross-sectional view of the combined seat 170 and stem 180 of FIG. 11A.

(132) It can be seen that a shoulder of the seat 170 rests on the proximal end 192 of the lower sub 190. In this respect, the distal end 184 of the stem 180 flanges out to serve as a base for threadedly connecting the stem 180 and seat 170. An annular seal 171 is placed between an inner diameter of the seat 170 and an outer diameter of the stem 180. The seat 170 and stem 180 are connected to form an integral body, supported by the lower sub 190.

(133) As noted above, an annular seal 171 is placed along an inner diameter of the seat 170 and an outer diameter of the stem 180. The annular seal 171 represents an enlarged, high density o-ring that may be fabricated, for example, from synthetic rubber and fluoropolymer elastomers. An example is a polymer seal provided by The Chemours Company FC, LLC of Wilmington, Del. Seals and o-rings are available from The Chemours Company under the Viton brand.

(134) With the tool designs of FIGS. 1A and 2A, once the tool 100 or 200 shifted modes and the plunger 160 landed on the seat 170 (more specifically, the annular seal 171) the pump-rate should be increased by approximately 10% for the plunger 160 to provide sufficient compression on the Viton material in order to create a true fluid seal. This all happens within the pump-rate specified for the orifice size the tool 100 or 200 is configured with; however, some users may see the pressure increase (indicated flow-thru/milling mode) and assume the transition was complete, but this is not necessarily the case since there would still be fluid weeping out of the annular ports 181 at this time. With the third embodiment 1200, once the mandrel 155 and connected plunger 1260 move down and the radial slots 1281 the plunger 1260 have crossed the ID seals 1275 in the seat 1270, the mode change is complete and will coincide with the moment the user observes the pressure indication.

(135) As an alternative to the clean-out tool 100 and its annular seal 171, a third embodiment of a clean-out tool is presented herein In this embodiment, the annular seal 171 and the stem 180 are removed. This alternative clean-out tool is presented at 1200 in FIGS. 12A, 12B and 12C.

(136) FIG. 12A is a cross-sectional view of the clean-out tool 1200, in the third embodiment. In this view, the clean-out tool (or flow diverter) 1200 is again in its run-in position wherein a significant portion of injected clean-out fluid flows to back jetting ports 148, while a remaining portion flows through the end of the tool 1200. Specifically, a portion of the clean-out fluids flow through the bore 195 of the lower sub 190.

(137) The clean-out tool 1200 is built in accordance with the clean-out tool 100 described above. However, in FIG. 12A a new seat design 1270 is provided. Of importance, the stem 180 from FIG. 1A has been removed from the seat 1270. In addition, the slots 181 that previously resided within the stem 180 are now placed within a modified plunger 1260.

(138) The seat 1270 represents an essentially tubular body secured proximate the lower end 144 of the back jet housing 140. Specifically, the seat 1270 resides along an inner diameter of the back jet housing 140, and sits on top of the top end 192 of the lower sub 190. O-rings (not numbered) are suitably placed along the inner and outer diameters of the seat 1270. In this way, seals are placed along the interfaces with the back jet housing 140 and the lower sub 190. In addition, the through-opening of the seat 1270 is dimensioned to slidably receive the plunger 160.

(139) FIG. 12A-P1 is a cross-sectional view of portion P1 of FIG. 12A. P1 represents an enlarged view of area P1, showing the relationship between a modified plunger 1260 and the modified seat 1270. The modified plunger 1260 has an upper (or upstream) end 1262 and an opposing lower (or downstream) end 1264. A bore 1265 is formed from the upper 1262 to the lower 1264 end, allowing the clean-out fluid to flow through the plunger 1260. The upper end 1262 comprises male threads that connect to the lower end 154 of the mandrel 155. In this way, the modified plunger 1260 still moves up and down along the bore 105 of the clean-out tool 1200 with the mandrel 155.

(140) It can be seen that the plunger 1260 has only partially entered the through-opening of the seat 1270. This is the default, or run-in position of the clean-out tool 1200. Here, the clean-out tool 1200 is in its back-jetting (or clean-out) mode. In the back-jetting mode, the operator pumps clean-out fluid into the working string and the bore 105 of the tubular housing below the activation rate.

(141) In the arrangement of FIG. 12A, the radial slots 1281 are positioned above the seat 1270. This allows a significant portion of the clean-out fluids to flow back up the annular region 145 around the mandrel 155, and through the jetting ports 148. Beneficially, no stem 180 is required.

(142) FIG. 12B is a second cross-sectional view of the clean-out tool 1200 of FIG. 12A. Here, the clean-out tool 1200 is translating from its raised position to an intermediate position. In this position, a significant portion of the injected fluid continues to flow through the radial slots 1281 and on to the back jetting ports 148. The remaining portion of injected fluid will continue to flow down through the seat 1270 and the end of the tool 1200.

(143) FIG. 12B-P2 is an enlarged cross-sectional view of portion P2 of FIG. 12B. Here, it can be seen that the plunger 1260 has approached the seat 1270. However, the radial slots 1281 still reside above the seat 1270.

(144) FIG. 12C is a third cross-sectional view of the clean-out tool 1200 of FIG. 12A. Here, the flow diverter tool 1200 has been cycled to its fully lowered position. In this position, the plunger 1260 has landed on the seat 1270. Specifically, a shoulder 1278 along the plunger 1260 has landed on an upper end of the seat 1270.

(145) FIG. 12C-P3 is an enlarged cross-sectional view of portion P3 of FIG. 12B. Here, it can be seen that the plunger 1260 has passed across the seat 1270. The radial slots 1281 have passed the seat 1270, forcing all clean-out fluids to flow through the bottom of the tool. In this position, virtually no clean-out fluid is diverted to the back jetting ports 148.

(146) The benefit to this third embodiment 1200 is that the tool does not rely on the Viton seal 171 to close off flow to the back-jetting ports 148. This avoids the potential issue of the seal 171 degrading over time. Instead, much smaller o-rings 1275 (or, optionally, PTFE seals energized by o-rings) are provided along the inner and outer diameters of the seat 1270, providing a more reliable design.

(147) In one aspect, an inner diameter of the plunger 1260 below the radial slots 1281 can be tuned to adjust a flow split of clean-out fluid while the clean-out tool 1200 is in its back-jetting mode. This enables the inner diameter of the plunger 1260 below the radial slots 1281 to be reduced completely to zero in order to direct the entire flow to the back jetting ports during back-jetting mode.

(148) FIG. 12-P4 is another enlarged cross-sectional view of portion P1 of FIG. 12A. The radial slot 1281 once again are positioned above the seat 1270. However, in this arrangement a lower portion 1264 of the plunger 1260 has a restricted flow-through channel 1268. This is similar to what was done with the distal end 184 of the stem 180 shown in FIGS. 2A, 2B and 2C.

(149) FIG. 12-P5 is still another enlarged cross-sectional view of portion P1 of FIG. 12A. The radial slots 1281 once again are positioned above the seat 1270. However, in this arrangement a lower portion 1264 of the plunger 1260 is closed off. In this instance, the lower portion 1264 is a solid body. The solid body may be fabricated from steel, plastic or an elastomeric material.

(150) Of interest, in the embodiment of FIG. 12-P5, when the clean-out tool 1200 is in its the second setting, the operator may vigorously inject a working fluid into the tubular housing 110 to clean out the wellbore without losing a portion of the working fluid through the seat 1270.

(151) In any embodiment, the clean-out tool 100, 200, 1200 (with or without tool 300 or some bottom hole assembly below) is intended to be run into a wellbore. FIG. 13 is a cross-sectional view of an illustrative wellbore 1300. The wellbore 1300 penetrates into a subsurface formation 1350. The wellbore 1300 has been completed as a cased-hole completion for producing hydrocarbon fluids. More importantly for purposes of the present disclosure, the wellbore 1300 has received a multi-cycle clean-out tool such as the tool 1200 of FIG. 12A.

(152) It can be seen that the wellbore 1300 has been completed with a series of pipe strings referred to as casing. First, a string of surface casing 1310 has been cemented into the formation 1350. The cement resides in an annular region 1315 around the casing 1310, forming an annular sheath 1312. The surface casing 1310 has an upper end in sealed connection with a bottom wellhead valve 1364.

(153) Next, at least one intermediate string of casing 1320 is cemented into the wellbore 1300. The intermediate string of casing 1300 is in sealed fluid communication with a top wellhead valve 1362. A cement sheath 1322 resides in an annular region 1325 of the wellbore 1300. The combination of the casing 1310/1320 and the cement sheaths 1312, 1322 in the annular regions 1315, 1325 strengthens the wellbore 1300 and facilitates the isolation of aquitards and formations behind the casing 1310/1320. It is understood that a wellbore 1300 may, and typically will, include more than one string of intermediate casing.

(154) Finally, a production string 1330 is provided. The production string 1330 is hung from the intermediate casing string 1320 using a liner hanger 1331. The production string 1330 is a liner that is not tied back to the surface 1301. In the arrangement of FIG. 13, a cement sheath 1332 is provided around the liner 1330. The cement sheath 1332 fills an annular region 1335 between the liner 1330 and the surrounding rock matrix in the subsurface formation 1350.

(155) The production liner 1330 has a lower end 1334 that extends to an end 1354 (or toe) of the wellbore 1300. For this reason, the wellbore 1300 is said to be completed as a cased-hole well. Those of ordinary skill in the art will understand that for production purposes, the liner 1330 will be perforated after cementing to create fluid communication between a bore 1345 of the liner 1330 and the surrounding rock matrix making up the subsurface formation 1350. In one aspect, the production string 1330 is not a liner but is a casing string that extends back to the surface. In this instance, the cement sheath 1332 will not be extended to the surface 1301.

(156) As an alternative, end 1354 of the wellbore 1300 may include joints of sand screen (not shown). The use of sand screens with gravel packs allows for greater fluid communication between the bore 1345 of the liner 1330 and the surrounding rock matrix 1350 while still providing support for the wellbore 1300. In this instance, the wellbore 1300 would include a slotted base pipe as part of the sand screen joints. Of course, the sand screen joints would not be cemented into place.

(157) It is also noted that the bottom end 1354 of the wellbore 1300 is completed substantially horizontally. This is a common orientation for wells that are completed in so-called tight or unconventional formations. Indeed, in the United States well over half of all wells are now completed horizontally. In the wellbore 1300 of FIG. 13, the horizontal portion extends along a pay zone 1355.

(158) Horizontal completions not only dramatically increase exposure of the wellbore to the producing rock face, but also enable the operator to create fractures that are substantially transverse to the direction of the wellbore. Those of ordinary skill in the art may understand that a rock matrix will generally part in a direction that is perpendicular to the direction of least principal stress. For deeper wells, that direction is typically substantially vertical. However, the present inventions have equal utility in vertically completed wells or in multi-lateral deviated wells.

(159) When completed, the wellbore 1300 will include a string of production tubing (not shown). However, before that is done, it is desirable to clean out the wellbore 1300. Accordingly, the wellbore 1300 includes the clean-out tool 1200 as shown in FIGS. 12A-12C.

(160) It is noted that the clean-out tool 1200 is connected to a string of coiled tubing 1340. The coiled tubing string 1340 serves as a working string for delivering an aqueous fluid under high pressures downhole. Such pressures may exceed 500 psi, or even 3,000 psi. The clean-out tool 1200 is preferably extended along the horizontal leg of the wellbore 1300 through the pay zone 1355.

(161) A lubricator 1360 or frac tree is placed over the wellbore 1300. The lubricator 1360 is positioned at the surface 1301 to control wellbore pressures during a completion (or other wellbore) operation and to isolate tools such as a string of coiled tubing 1340 being moved into and back out of the wellbore 1300. A surfactant may be added to the clean-out fluid to assure that the fluid moves through the clean-out tool 1200 and up the wellbore 1300. Preferably, the fluid is filtered to minimize plugging of back jetting ports 148.

(162) In one aspect, the coiled tubing string 1340 is dimensioned to be inserted into a string of production tubing (not shown). In this way, the production tubing may be cleaned out after a period of production.

(163) Using any of the flow diverters 100, 200 or 1200 described above, a method 1400 of conducting a wellbore operation is also provided. The method 1400 is presented in the flow chart of FIG. 14.

(164) The method 1400 first includes providing a wellbore. This is indicated at Box 1410. The wellbore is being completed for the production of hydrocarbon fluids. Of interest, the wellbore has been formed with a string of casing, including a string of production casing along a selected subsurface formation.

(165) The wellbore may be completed vertically. Alternatively, the wellbore may be a deviated well formed from a lateral drilling operation. More preferably, the wellbore is completed horizontally as shown in FIG. 13. However, the methods are not limited to the orientation of the wellbore unless expressly stated in the claims.

(166) It is understood that for purposes of Box 1410, the term providing includes but is not limited to forming or completing. The term providing may also mean that a service company accesses a wellbore that has already been drilled and completed, or accesses a wellbore that has been undergoing production operations for a period of time.

(167) The method 1400 also includes running a clean-out tool into the wellbore. This is provided in Box 1420. The clean-out tool is run into the wellbore at the lower end of a string of coiled tubing 1340. The clean-out tool may be constructed in accordance with any of the embodiments 100, 200, 1200 described above. Particularly, the clean-out tool is a multi-cycle tool having a tubular housing that includes an elongated bore. Fluids are pumped from the surface, down the string of coiled tubing, and into the bore.

(168) The clean-out tool includes one or more back jetting ports. At least some of the ports are disposed at an upward angle. In this way, injected clean-out fluids flow through the ports and exit the clean-out tool at an upward angle to sweep any particles or debris in the casing toward the surface (or at least upstream).

(169) The method 1400 additionally includes locating the clean-out tool. This is seen at Box 1430. The clean-out tool is located at a selected depth along a tubular body within the wellbore. Subsurface formation 1355 of FIG. 13 is an example of a location or depth for the clean-out tool. The term depth may include total depth a selected distance along a horizontal wellbore.

(170) The method 1400 further includes pumping a clean-out fluid down the coiled tubing string. This is provided at Box 1440. The fluid is a hydraulic fluid that is pumped into the wellbore under pressure. The fluid is pumped down the coiled tubing and into the bore of the tubular housing making up the clean-out tool at a first flow rate. The first flow rate is below an activation rate. The pumping at the first flow rate causes at least a portion of clean-out fluid to flow through the mandrel, through radial slots, back up the lower annular region and through the back jetting ports. This step of Box 1440 is illustrated in FIG. 12A.

(171) It is again noted that in the arrangement of FIG. 12-P4, the lower end 1264 of the plunger 1260 is significantly restricted. In this instance, a majority of the clean-out fluid flows back through the back jetting ports when the clean-out tool is in its back-jetting mode. In the arrangement of FIG. 12-P5, the lower end 1264 of the plunger 1260 is completely closed off In this instance, all clean-out fluid flows back through the back jetting ports when the clean-out tool is in its back-jetting mode

(172) The method 1400 also includes further pumping the clean-out fluid down the coiled tubing and into the bore of the tubular housing at a second flow rate. This is shown at Box 1450. The second flow rate is higher than the first flow rate. In this instance, the higher flow rate increases a hydraulic force acting on a pressure shoulder of a piston, causing a mandrel and connected plunger to slide along a tubular housing such that the plunger passes along a through-opening in the seat. The radial slots in the plunger move below the seat. The result is that all of the injected clean-out fluid now flows through a distal end of the tool. This step of Box 1450 is illustrated in FIG. 12C.

(173) To effectuate the method 1400, it is preferred that a sequencing mechanism be placed along the tubular housing. The sequencing mechanism may be a J-slot mechanism. The J-slot mechanism may be configured to cycle between three settings. Those include: (i) a first setting wherein a pin associated with the J-slot mechanism resides in a first slot that places the plunger in a raised position in response to a biasing mechanical force exerted by a spring on the mandrel while pumping at a first rate, placing the clean-out tool in a back-jetting mode (shown in FIGS. 1A, 2A and 12A); (ii) a second setting wherein the pin moves higher in the first slot in response to the injection of fluids into the wellbore at a second increased rate, placing the plunger into an intermediate position while allowing the tool to remain in its back-jetting mode (shown in FIGS. 1B, 2B and 12B); (iii) the first setting again wherein the pin resides in a second slot that keeps the plunger in the raised position in response to the upward biasing force of the spring; and (iv) a third setting wherein the pin moves higher along a third slot in response to the injection of fluids into the wellbore at a second increased rate, and wherein the plunger slides from the raised position to the lowered position, placing the clean-out tool in its flow-through mode (shown in FIGS. 1C, 2C and 12C).

(174) It is observed that the second increased rate is an activation rate. The pump rate in both the second setting and the third setting may be higher than the activation rate.

(175) Additional steps may be taken in connection with the method 1400. These relate to tuning the various openings along the tool in order to provide a desired total cross-sectional area of fluid flow. Such steps are presented in Box 1460.

(176) For example, Box 1460 may include a step of adjusting an aperture size of an orifice associated with the piston. This has the effect of varying flow rates associated with the raised and lowered positions. In order for the clean-out tool to change modes, the piston orifice needs to be sized small enough to ensure the required activation rate will be achievable during the operation. Although the clean-out tool will change modes correctly, sizing the piston orifice too small for a planned pump-rate will cause excessive and unnecessary pressure drop that may limit the total flow capacity of the operation in back-jetting mode. Optimally, the piston orifice is sized appropriately to ensure the activation rate will be achievable in both modes throughout the operation with minimal back-pressure.

(177) Additionally, in connection with the first two embodiments herein the step of Box 1460 may also include adjusting a through-opening size of an orifice associated with the seat. Preferably, the orifice is part of a stem placed within the seat. In connection with the third embodiment herein, the step of Box 1460 may include adjusting a through-opening size at the bottom of the plunger. In both instances, a larger through-opening enables more working fluid to flow through the bore of the clean-out tool and less fluid to back flow to the back jetting ports during back-jetting mode. Reciprocally, a smaller through-opening allows less fluid to flow through the bore of the clean-out tool and more fluid to back flow to the back jetting ports during back-jetting (or clean-out) mode.

(178) Additionally, Box 1460 may also include a step of adjusting a size of the back jetting ports. When used with a clean-out tool below the seat, such as a Helix nozzle, the back jetting ports should be sized large enough to provide a significantly reduced pressure drop to enable increasing the annular velocity and desirable rate split between the back-jet housing and the Helix while in back-jetting mode. At the same time, the ports should be small enough to provide ample flow restriction for effective jetting.

(179) Additionally, in connection with the first two embodiments herein the Box 1460 may include the step of selecting a cross-sectional area for the flow through the radial slots in the stem. The process of selecting total cross-sectional areas through which clean-out fluids may flow is shown in Box 1460.

(180) It is observed that while Box 1460 is shown at the end of the flow chart for the method 1400 of FIG. 14, it is understood that these steps may and likely will be taken during tool design and before the tool is run into the wellbore in Box 1420.

(181) As can be seen, unique multi-cycle wellbore clean-out tools have been provided. The clean-out tools act as a flow diverter that increases the efficiency of fill removal operations. Fluid flow can also be sent through the tool to an optional bottom hole assembly below while having fluid communication with a back-jetting housing. The cycling of fluid flow modes is possible an unlimited number of times and does not require dropping a ball or reversing circulation.

(182) The modes of the clean-out tool may be manipulated through a combination of flow rate and sequence. Feedback is received at the surface through pump pressure indication. In a first setting, flow rate to the clean-out tool is below an activation rate. This allows the fluid flow to be in communication with the back jet housing as well as a nozzle or any bottom hole assembly or other tool that may be placed below the clean-out tool. In other words, the flow is split between the back jetting ports and a downstream nozzle. This is shown in FIGS. 1A, 2A and 12A as well as FIG. 4A.

(183) An activation rate is selected for moving the clean-out tool from its first setting to a second setting. In the second setting, the mandrel and connected plunger begin to slide down the tubular housing towards the seat. The activation rate is based on orifice cross-sectional area selection and may be pre-determined for a specific application.

(184) In the second setting, the plunger will not pass through the seat; instead, downward movement will be restricted by the sequencing mechanism. The use of a sequencing mechanism for cycling allows the operator to pump at a high flow rate (that is, above the activation rate) during back-jetting mode, increasing annular velocity for fill removal in the second setting. Additionally, orientation and selected cross-sectional area of the ports in the back-jetting housing aids in sweeping solids from the casing. This is shown in FIGS. 1B, 2B and 12B as well as FIG. 4B.

(185) To advance the sequencing mechanism, the operator will reduce the pump rate back down to or below the first rate. The clean-out tool defaults back to its back-jetting mode.

(186) In a third setting, flow rate is moved back up to, and above, the activation rate. This will advance the sequencing mechanism and allow the plunger to fully land on the seat. This is shown in FIGS. 1C and 2C as well as FIG. 4C. Alternatively, this will allow the radial slots in the plunger to pass across the seat as shown in FIG. 12C. In this position the clean-out tool is in its flow-through mode. The tool will direct the entire flow through to the nozzle or BHA below. Confirmation of this mode is given through an increase of pump pressure due to the entire flow now exiting through the bottom of the clean-out tool as opposed to a split between the back-jetting ports and the bottom of the clean-out tool.

(187) In the scenario of a plunger 1260 where no through-bore is provided below the radial slots 1281, the clean-out tool 1200 will need to be configured to provide a difference in pressures between a majority of the flow rate being directed to the back jetting ports versus through to the bottom-hole assembly below. In this way, a surface indication of the clean-out tool's mode may be detected.

(188) To return to the back-jetting mode, the flow rate may be reduced to a minimum pump-rate until pump pressure has stabilized. The tool will remain in back-jetting mode (FIGS. 1B, 2B and 12B) following a subsequent increase in flow rates, even above the activation rate. The tool will continue to remain in this back-jetting mode when the flowrate is lowered down to the minimum pump-rate (FIGS. 1A, 2A and 12A).

(189) As can be seen, an improved flow diverter tool 100, 200, 1200 for wellbore clean-out operations has been provided. The tool can be used for almost any coiled tubing application wherein fluid is circulated downhole.

(190) In one aspect, the clean-out tool is part of a bottom hole assembly that includes a downhole tool. The downhole tool is threadedly (or otherwise operatively) connected to the lower end of the lower sub. An upper end of the lower sub supports or is abutted against or otherwise resides proximate to the seat.

(191) In one embodiment, the downhole tool is a positive displacement motor. The positive displacement motor is configured to rotate a connected mill bit in response to hydraulic pressure received when the clean-out tool is in its clean-out mode. In a preferred application, the downhole tool is a positive displacement motor, such as motor 300 and is used for a milling operation.

(192) Generally, milling operations are used to remove scale, cement or consolidated fill in a wellbore. Milling operations may also be conducted to remove plugs that have been placed in the well bore. For milling, the operator may mill a first plug using the fluid flow-through mode, then switch the tool to back to its back-jetting mode to circulate out cuttings at a higher rate. The tool can then be cycled back to the fluid flow-through mode and continue to the next plug for milling again. The tool allows for higher circulation rates without over-running the motor, achieving higher annular velocities.

(193) Alternatively, a nozzle may be placed below the flow diverter tool. The nozzle may be any type of nozzle such as a so-called wash nozzle, a hydraulic jetting nozzle, a high pressure rotary nozzle or a pulsating wash tool. The nozzle serves to agitate fill that may have collected in the wellbore, facilitating clean-out in the wellbore while the tool is translated.

(194) It is observed that various nozzles alternative to the Helix nozzle mentioned above may be used below the clean-out tool 100, 200, 1200. For example, a nozzle for jet drilling such as is disclosed in U.S. Pat. No. 6,668,948 may be used. Alternatively, any of the rotary nozzles as disclosed in U.S. Patent Publ. No. 2016/0160619 may be employed. Alternatively still, the internally rotating nozzle of U.S. Pat. No. 9,845,641 may be used.

(195) As an alternative to a nozzle, the lower sub may be threadedly connected to a bottom hole assembly that includes a sliding sleeve shifting tool. The clean-out tool allows the operator to generate a back jetting flow rate above the activation rate of the sliding sleeve shifting tool for wellbore cleanout while the bottom hole assembly is in the wellbore. This may be done without prematurely activating the sliding sleeve shifting tool. The sliding sleeve shifting tool may be part of a BHA containing an extended reach tool, such as an NOV agitator tool. Wellbore clean-out can be conducted to a target depth before activating the sliding sleeve shifting tool at its activation rate.

(196) FIG. 3B presents an example of a suitable sliding sleeve shifting tool 300B. This illustrative tool 300B is a bi-directional shifting tool that is available from Hunting Energy Services, LLC of Houston, Tex.

(197) In one application, the flow diverter tool 100, 200, 1200 is run into a lateral bore hole. In this instance, a whipstock is placed immediately below the lateral bore hole and the flow diverter tool is then run into the wellbore and against the concave face of the whipstock.

(198) The flow diverter tool 100, 200, 1200 may also be used in connection with drilling operations. Specifically, the tool can be placed along a coiled tubing string wherein a well is being deepened, or wherein a side tracking operation is being conducted. In operation, the operator drills out a section of the well with the flow diverter tool in the fluid flow-through mode using a positive displacement motor 300A in conjunction with a milling tool or a drill bit. An illustration milling tool 300F is shown in FIG. 3F, while an illustrative drill bit 300G is presented in FIG. 3G. The illustrative milling tool 300F and drill bit 300G are each provided by Schlumberger of Sugar Land, Texas. In either instance, the operator switches the tool to its back-jetting mode and circulates out cuttings at a higher pumping rate. The operator then switches back to the fluid flow-through mode and drills another section of the wellbore. In a drilling operation, the tool again allows for higher circulation rates without over running the motor, achieving higher annular clean-out velocities.

(199) The flow diverter tool 100, 200, 1200 may further be used with a back pressure valve during underbalanced situations. In such situations the operator may use a column of nitrogen to lighten the hydrostatic head. After milling a plug and any fill that is encountered, the operator switches back to the back-jetting mode. During this mode, the operator can circulate nitrified fluid down the working string without circulating through the motor. It is noted that with many motors, nitrogen can shorten the life of the stator. Upon circulating the string back to fluid again the operator can switch modes and continue the milling operation.

(200) Of interest, the flow diverter tool 100, 200, 1200 can also be run with setting tools or shifting tools. These include sliding sleeves and multi-stage frac sleeves. As noted above, FIG. 3B presents a sliding sleeve shifting tool 300B. An illustrative setting tool 300E is shown in FIG. 3E. This particular setting tool is manufactured by Alpha Oil Tools of Fort Worth, Texas. The flow diverter tool allows high clean-out circulations rates without activating a completion tool below, e.g., circulating above a shifting tool at a rate above the activation rate of the shifting toolwithout the possibility of activating the shifting mechanism in the tool.

(201) In a specific example, the operator may set a resettable bridge plug for a multi-stage fracturing operation with the flow diverter tool 100, 200, 1200 installed above the resettable bridge plug. In this instance, circulation remains possible through the back jetting ports without activating a hydraulically activated bridge plug below. In the case of a mechanically set plug, the flow diverter allows the operator to switch between circulating through the bottom of the plug when the plug is not set, and circulating above the plug when the plug is set.

(202) FIG. 3C presents an example of a suitable bridge plug 300C. This illustrative tool 300C is a Crownstone GTV tubing-retrievable well barrier (or retrievable bridge plug) that is available from Baker Hughes (a GE Company) also of Houston, Tex.

(203) In another embodiment, the flow diverter tool 100, 200, 1200 can be run in connection with an acid stimulation operation. In this instance, a high pressure jetting tool may be run below the flow diverter to remove scale, or clean perforations prior to acidizing. If the rate the formation takes the stimulation fluid is not a limiting factor, the tool can be shifted to divert flow to the larger back jet ports and the rate at which the job is pumped can be increased reducing time and increasing efficiency.

(204) The use of a back pressure valve may also be useful where a sensitive tool is positioned on the tool string below the flow diverter, and the operator wishes to ensure that the sensitive tool will not activate when in back-jetting mode. Basically, any operation where a tool below may restrict the amount of flow that is reasonably possible with the current work string. The tool can increase operational efficiency by either eliminating unneeded trips out of the hole to change tools or reduce operational time by allowing the operator to increase the flow rate and subsequently complete the job faster.

(205) Further, variations of the tool and of methods for cleaning out a wellbore may fall within the spirit of the claims, below. It will be appreciated that the inventions are susceptible to other modifications, variations and changes without departing from the spirit thereof.