The present invention relates generally to fluid flow systems useful in underground wells. In some embodiments, the present invention relates to systems, apparatus and methods capable of allowing fluid filtered through a screen to pass along the outside of a pipe disposed in a well bore to a pipe entry point near the end of the pipe.
In subsurface hydrocarbon recovery operations, some situations warrant the communication of fluid within the downhole assembly along the outside of a span of pipe. For example, during circulating gravel packing operations, it is often desirable to recover gravel delivery fluid through one or more fluid entry point at or near the bottom of the pipe. However, the delivery fluid typically initially enters the downhole assembly through screens located along a length of the pipe, requiring the fluid to be able to thereafter travel along the outside of the pipe to the desired entry point(s).
Various challenges may create difficulties in achieving effective fluid flow along the outside of a span of pipe in a well bore. In the gravel packing scenario above, there may be difficulties in directing the screen-filtered delivery fluid along the outside of the pipe to the desired pipe entry point downhole of the screens. For example, the inclusion of inflow ports or devices, such as inflow control devices (ICD), along the length of the pipe assembly may prevent fluid isolation (from inside the pipe) or impede flow along the desired path. For another example, the orientation of the well bore, such as in non-vertical wells or well sections, may hinder the ability of the fluid to flow in the desired path. As used herein, the term “non-vertical well” includes horizontal, lateral, inclined, deviated, directional or similar wells. In particular scenarios involving systems with ICDs deployed in horizontal wells, for example, the free circulating return of gravel pack carrier fluid would be difficult or impossible, preventing complete alpha/beta wave packing. In such instance, the wells would not be fully gravel packed, which can lead to problems during production.
Accordingly, there exists a need for apparatus, systems and methods useful with underground fluid flow systems having one or more of the following attributes, capabilities or features: allows the communication of fluid within a downhole assembly along the outside of a span of pipe disposed in a well bore; allows the communication of fluid in either direction within a downhole assembly along the outside of a span of pipe; allows screen-filtered fluid to pass at least substantially unrestricted past at least one inflow control device along the outside of a length of pipe to a desired pipe entry point near the end of the pipe; allows fluid to pass from the well bore through at least one screen jacket into the pipe at a desired entry point without at least substantial entry into the pipe therebetween; allows the recovery of gravel delivery fluid through one or more fluid entry point at or near the bottom of the pipe during gravel packing operations; allows the recovery of gravel delivery fluid through one or more fluid entry point at or near the bottom of the pipe during gravel packing operations without the need for a wash pipe; allows effective free circulating return of gravel pack carrier fluid during gravel packing operations in non-vertical wells; allows alpha/beta wave gravel packing of non-vertical wells in which ICD type screen assemblies are deployed; or any combination thereof.
It should be understood that the above-described examples, features and/or disadvantages are provided for illustrative purposes only and are not intended to limit the scope or subject matter of the appended claims or any other patent application or patent claiming priority hereto. Thus, none of the appended claims or claims of any related application or patent should be limited by the above discussion or construed to address, include or exclude the cited examples, features and/or disadvantages, except and only to the extent as may be expressly stated in a particular claim.
In some embodiments, the present disclosure involves apparatus useful for allowing fluid flow inside at least one screen and outside a span of pipe disposed in a well bore. The apparatus includes a tubular assembly having an upper portion, a lower portion and a bore extending therebetween. The upper and lower portions and the bore are disposed along a longitudinal axis of the tubular assembly. At least one inlet is formed in the lower portion of the tubular assembly and allows fluid communication between the bore and the exterior of the tubular assembly. At least a first screen is in fluid communication with the well bore and at least partially concentrically surrounds at least part of the tubular assembly. The screen is disposed along the longitudinal axis of the tubular assembly at a location above the inlet.
In these embodiments, at least a first port is formed in the tubular assembly at a location above the inlet. The first port allows fluid communication between the bore and the exterior of the tubular assembly. At least a first ICD at least partially concentrically surrounds at least part of the tubular assembly over the first port, and is disposed along the longitudinal axis of the tubular assembly at a location between the upper end of the first screen and the inlet(s). At least one flow path for fluid entering the screen extends along the exterior of the bore of the tubular assembly at least partially along the longitudinal axis thereof. The flow path is at least substantially fluidly isolated from the port(s) and extends from the first screen to the inlet. Fluid is capable of at least substantially unrestricted flow between the screen(s) and inlet(s) without at least substantially entering the bore of the tubular assembly therebetween.
There are embodiments of the present disclosure involving apparatus useful for allowing the flow of fluid into a fluid flow system disposed in a well bore during gravel packing operations. The apparatus includes a tubular assembly having upper and lower ends and at least one port that allows fluid communication between the interior and exterior of the tubular assembly. A first ICD extends at least partially around at least part of the tubular assembly over at least one port. At least one screen extends around at least part of the tubular assembly over the first ICD. The screen forms an annulus around the tubular assembly. The annulus includes a gap disposed between the screen and the first ICD. At least one inlet is formed in the tubular assembly between the screen(s) and the lower end of the tubular assembly. The inlet is in fluid communication with the annulus and the interior of the tubular assembly. Fluid may flow from the well bore through the screen(s), into and through the annulus, through the gap at least substantially around the first ICD and port(s) and into the tubular assembly through the inlet(s) without the necessity of a wash pipe.
In many embodiments, the present disclosure involves apparatus for allowing the flow of fluid into a fluid flow system disposed in a well bore during gravel packing operations. A tubular assembly has upper and lower ends and at least one port that allows fluid communication between the interior and exterior of the tubular assembly. A first ICD extends at least partially around at least part of the tubular assembly over at least one port. The first ICD includes at least one flow restriction mechanism useful to control the flow of fluid through the port. The first ICD also includes at least one bypass flowway through which fluid may flow at least substantially around the flow restriction mechanism and port.
In these embodiments, at least one screen extends around at least part of the tubular assembly adjacent to the first ICD. The screen forms an annulus around the tubular assembly. The annulus is in fluid communication with the bypass flowway of the first ICD. At least one inlet is formed in the tubular assembly proximate to the lower end thereof below the first ICD and the screen(s). The inlet is in fluid communication with the annulus, the bypass flowway and the interior of the tubular assembly. Fluid may flow from the well bore through the screen(s), into and through the annulus and the bypass flowway and into the tubular assembly through the inlet without the necessity of a wash pipe.
Various embodiments of the present disclosure involve a system useful for allowing fluid filtered through a screen jacket to pass along a length of pipe having multiple ICDs and disposed in a well bore to a desired pipe entry point near the end of the pipe. A tubular assembly includes an upper end, a lower end and a bore extending therebetween. At least one inlet is formed proximate to the lower end of the tubular assembly and allows fluid communication between the bore and the exterior of the tubular assembly. At least one closure member is selectively operable to open and close the inlet(s).
In these embodiments, at least first and second axially aligned screen assemblies each include at least one screen jacket and base pipe. The bore of the tubular assembly extends through each base pipe. Each screen jacket at least partially concentrically surrounds at least part of its associated base pipe. Each base pipe includes at least one port formed therein. The ports are capable of allowing fluid communication between the bore and the exterior of the tubular assembly and are disposed above the inlet. At least first and second ICDs are disposed above the at least one inlet. Each ICD is associated with at least one port and is capable of controlling the flow of fluid therethrough.
Also in these embodiments, at least one fluid communication assembly is disposed between the first and second screen assemblies, is in fluid communication with the first and second screen jackets and is fluidly isolated from the bore of the tubular assembly. At least one flow path extends along the interior of the screen jackets and exterior of the base pipes to the inlet(s). The flow path passes through the fluid communication assembly and either passes through or around the ICDs in at least substantial fluid isolation from the ports. When the inlet is open, the flow path allows fluid to pass from the well bore through the screen jacket(s) and the inlet(s) into the bore of the tubular assembly without at least substantial entry into the bore therebetween.
There are embodiments of the present disclosure that involve methods of allowing gravel packing of substantially the entire well bore annulus around a tubular assembly disposed in a well bore. These methods involve the use of a tubular assembly having at least one closable inlet. The tubular assembly also includes at least one screen and at least one ICD disposed between the inlet and the upper end of the tubular assembly. At least one flow path extends and allows fluid flow between each screen and at least one inlet on the outside of the bore of the tubular assembly. The flow path at least substantially bypasses the flow restriction mechanisms of the ICD(s).
Now in accordance with the methods of these embodiments, with the inlet(s) open, gravel delivery fluid from the well bore is allowed to enter through the screen(s) and into the flow path(s) during the alpha wave formation. The screen filtered gravel delivery fluid is allowed to flow in the flow path(s) outside the bore of the tubular assembly to the inlet(s) and allowed to enter the bore through the inlet(s). After the alpha wave is formed, gravel delivery fluid from the well bore is allowed to enter through the screen(s) and into the flow path(s) during the beta wave formation. The screen filtered gravel delivery fluid is allowed to flow in the flow path(s) outside the tubular assembly bore to the inlet(s) and allowed to enter the bore through the inlet(s). At a desired time, the inlet(s) may be closed, such as to allow formation fluid to pass from the well bore through the screen(s) into the ICDs for controlled entry in the tubular assembly through at least one other entry port.
Accordingly, the present disclosure includes features and advantages which are believed to enable it to advance underground fluid flow technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of various embodiments and referring to the accompanying drawings.
The following figures are part of the present specification, included to demonstrate certain aspects of various embodiments of this disclosure and referenced in the detailed description herein:
Characteristics and advantages of the present invention and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of exemplary embodiments of the claimed invention and referring to the accompanying figures. It should be understood that the description herein and appended drawings, being of example embodiments, are not intended to limit the appended claims or the claims of any patent or patent application claiming priority hereto. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claims. Many changes may be made to the particular embodiments and details disclosed herein without departing from such spirit and scope.
In showing and describing preferred embodiments, common or similar elements are identified by like or identical reference numerals or are apparent from the appended drawings themselves. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
As used herein and throughout various portions (and headings) of this specification, the terms “invention”, “present invention” and variations thereof are not intended to mean the invention of every possible embodiment of the invention or any particular claim or claims. Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment of the invention or any particular claim(s) merely because of such reference. Also, it should be noted that reference herein and in the appended claims to components and aspects in a singular tense does not necessarily limit the present invention to only one such component or aspect, but should be interpreted generally to mean one or more, as may be suitable and desirable in each particular instance.
Referring initially to
The illustrated fluid flow system 10 includes a tubular assembly 20 comprising one or more tubular member 25 and generally having an upper portion 21, a lower portion 22 and at least one bore 26 extending therebetween. The bore 26 allows one or more downhole operations to be conducted from the surface, such as, for example, fluid communication, oil/gas recovery and tool deployment as is and becomes further known. The upper and lower portions 21, 22 of the tubular assembly 20 and the bore 26 are disposed along a longitudinal axis 28 of the tubular assembly 20.
At least one inlet 46 is provided in the lower portion 22 of the exemplary tubular assembly 20 and at least one port 24 is formed in the tubular assembly 20 above the inlet(s) 46. The inlet(s) 46 and port(s) 24 are capable of allowing fluid communication between the bore 26 and the exterior 23 of the tubular assembly 20, as described further below and as is or becomes further known.
Still referring to the example of
In the illustrated embodiment, at least one inflow control device 30 is associated with the tubular assembly 20 and at least one port 24 formed therein. In this example, the ICD 30 concentrically surrounds part of the assembly 20 over the port 24. The ICD 30 is disposed along the longitudinal axis 28 of the tubular assembly 20 at a location above the inlet(s) 46.
The ICD 30 is typically useful during hydrocarbon production operations to limit, control or affect the inflow of formation fluids into the bore 26 of the tubular assembly 20 via the associated port(s) 24, as is and becomes further known. The ICD 30 often includes at least one inflow aperture 32 into the ICD 30 and at least one flow restriction mechanism 31 to affect the fluid flow rate through the port 24. The flow restriction mechanism 31 may include, for example, at least one tortuous flow path, profile arrangement, expandable or swellable member, adjustable throttling or valve device such as a remotely controllable sleeve assembly, or a combination thereof, as is or becomes further known. However, the present invention and appended claims are not limited to any of the above details. As used herein and in the appended claims, the terms “inflow control device” and variations thereof include any one or more devices, features, components or mechanisms disposed between the bore and exterior of a pipe and which in some way affects the flow therebetween.
Further information about various exemplary inflow control devices and their construction, operation and other details may be found in publicly available documents, including, without limitation, U.S. patent application Ser. No. 11/946,638 filed on Nov. 28, 2007, entitled “Flow Restriction Apparatus and Methods” and having a common assignee as this patent, U.S. Patent Application Publication No. US 2007/0246407 to Richards et al., published on Oct. 25, 2007 and entitled “Inflow Control Devices for Sand Control Screens”, U.S. Pat. No. 5,435,393 to Brekke et al., entitled “Procedure and Production Pipe for Production of Oil or Gas Fran an Oil or Gas Reservoir” and issued on Jul. 25, 1995, U.S. Pat. No. 5,896,928 to Conn, entitled “Flow Restriction Device for Use in Production Wells” and issued on Apr. 27, 1999, U.S. Pat. No. 6,112,815 to Boe et al., entitled “Inflow Regulation Device for a Production Pipe for Production of Oil or Gas From an Oil and/or Gas Reservoir” and issued on Sep. 5, 2006, SPE 103195 by Jody Augustine et al. entitled “World's First Gravel Packed Uniform Inflow Control Completion,” (Copyright 2006, Society of Petroleum Engineers), the Aramco ICD Specifications for Equalizer Type Completion dated Oct. 4, 2006 and entitled “Technical Parameters for ICD (Equalizer) Production System”, and the article entitled “New, Simple Completion Methods for Horizontal Wells Improve Production Performance in High-Permeability This Oil Zones” by Kristian Brekke and S. C. Lien published in the September 1994 issue of SPE Drilling and Completion, all of which are hereby incorporated by reference herein in their entireties. It should be noted that nothing contained in any of the above-referenced sources or any other source is limiting upon the present invention.
It should be understood that all of the above-described components and features may have any suitable or desired construction, configuration, components, operation and other details, none of which are in any way limiting upon the present invention unless and only to the extent as may be expressly provided in and with respect to any particular appended claims.
Still referring to the embodiment of
The flow path(s) 48 may extend through any desired number and types of components, as long as fluid is able to at least substantially flow between the screen(s) 34 and inlet(s) 46 outside the bore 26. In the particular view of
In this embodiment, each screen assembly 60, 62 includes a base pipe 66, at least one screen 34 and at least one ICD 30. The base pipes 66 each include at least one port 24 and an interior space 68 that forms part of the bore 26 of the assembly 20. In this example, the ICD 30 surrounds at least one port 24, and the screen 34 surrounds the associated ICD 30. An assembly annulus 40 is shown formed between each screen 34 and adjacent base pipe 20. The annulus 40 includes a gap 44 (e.g.
The screens 34 and ICDs 30 may be arranged in any other suitable configuration. For example, referring to
Still referring to the embodiment of
Referring back to the particular arrangement of
In the embodiment shown, the fluid communication assembly 70 includes a sleeve 73 sealingly engaged within the base pipes 66 proximate to their adjacent ends 67 (see e.g.
Further details and examples of fluid communication assemblies that may be used in connection with the present invention are described and shown in various publicly available documents, including without limitation, the brochure of the present assignee, BJ Services company, entitled “Screen Communication System Product Information” and U.S. Pat. No. 6,405,800 issued on Jun. 18, 2002 to Walker et al., entitled “Method and Apparatus for Controlling Fluid Flow in a Well” and having a common assignee of the present patent, both of which are hereby incorporated by reference herein in their entireties.
Still referring to the embodiment of
In this example, the valve assembly 80 also includes a closure member 88 selectively moveable over the inlet 46. The closure member 88 may be useful in some applications, for example, to close the inlet 46 when it is desired to pressurize the flow path 48 and allow production fluid flow from the formation 15 to pass into the inflow apertures 32 of the inflow control devices 30 and ports 24.
The illustrated closure member 88 is a sliding sleeve 90 movable between open and closed positions relative to the inlet 46 in any suitable manner. For example, the sleeve 90 may be movable with the use of a mechanical shifting tool or wash pipe (not shown) inserted in the bore 26 and operable as is or becomes further known. However, the closure member 88 may have any other suitable form, configuration and operation. For example, the closure member 88 may be a ball-valve or other type of valve, mechanism or other feature that is hydraulically, electrically, electronically or otherwise actuated. Thus, the present invention is not limited by the construction, components, configuration, operation and other details of the closure member 88. Moreover, a closure member 88 may not be included, and the inlet 46 may be selectively closed or blocked (if desired) in any suitable manner.
Still with reference to
In other embodiments, the valve assembly 80 may not comprise a separate component, but may be integral to the second screen assembly 60 or other component. For example, the inlet 46 may be formed directly in the second screen assembly 60 or lowermost tubular member 25 of the system 10 or another component welded to the tubular assembly 20, and a closure member 88 may be associated therewith. Moreover, a valve assembly 80 may not be included.
In another independent aspect, the present invention includes methods of allowing fluid filtered through at least one screen to flow outside the bore of a pipe disposed in a well bore to a pipe entry point at a desired location in the pipe span. An embodiment of a method will now be described with the use of the fluid flow system 10 of
However, it should be understood that the illustrated system 10 is not required for practicing this exemplary method or other methods of the present invention or the appended claims. Any suitable components may be used. Further, the present invention is not limited to the particular method as described below, but includes any method of allowing fluid flow within a fluid flow system along the exterior of a span of pipe disposed in a well bore in accordance with the principals of the present disclosure. Moreover, the apparatus, methods and systems of the present invention are not limited to use during gravel packing operations, but may be used in any scenario involving communication of fluid in either direction between the pipe interior and well bore where fluid flow along the exterior of a span of the pipe is desired. A few other examples where the invention may, in some instances, be useful include well stimulation, hole cleaning and fracturing packing.
Referring to the example shown in
During the insertion of the gravel slurry, gravel 94 from the slurry will typically settle in the well bore annulus 18 along the outside of the tubular assembly 20 beginning near the heel of the well bore 14 and progressing downhole in the well bore 14 along the outside of the tubular assembly 20 toward the toe (not shown) of the well bore 14. In this example, the “toe” of the illustrated well bore 14 would be to the right of the valve assembly 80. This gravel build-up or bank is sometimes known as and referred to herein as the alpha wave 96 and may, for example, fill approximately ¾ of the width of the well bore annulus 18. The alpha wave 96 is shown in
Still referring to
In this particular example, the flow path 48 includes the assembly annuluses 40 of the first and second screen assemblies 60, 62, the respective gaps 44 (see e.g.
In this example, there is no need for a wash pipe (not shown) or other component to assist in blocking ports 24 or other intermediate entry points into the bore 26, or to otherwise encourage fluid flow along the exterior 23 of the tubular members 25 to the inlet 46. After passing through the inlet(s) 46, the delivery fluid may then flow up the bore 26 as indicated by arrows 100 to the surface (not shown) or otherwise as desired.
Now referring to the exemplary illustration of
Still referring to
After the delivery fluid has sufficiently entered the bore 26 (or at any other time), the inlet 46 may be closed or blocked, such as by actuation of a closure member 88. This may be desired, for example, to allow the ICDs 30 to be the active inflow points into the bore 26 for production, or other operations.
It should be noted that in other applications, it may be desirable for fluid flow in the opposite direction through the flow path 48 from the bore 26 of the tubular assembly 20 to the well bore annulus 18. Thus, the present invention is not limited to flow into the bore 26.
Preferred embodiments of the present invention thus offer advantages over the prior art and are well adapted to carry out one or more of the objects of the invention. However, the present invention does not require each of the components and acts described above and is in no way limited to the above-described embodiments, methods of operation, variables, values or value ranges. Any one or more of the above components, features and processes may be employed in any suitable configuration without inclusion of other such components, features and processes. Moreover, the present invention includes additional features, capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims.
The methods that may be described above or claimed herein and any other methods which may fall within the scope of the appended claims can be performed in any desired suitable order and are not necessarily limited to any sequence described herein or as may be listed in the appended claims. Further, the methods of the present invention do not necessarily require use of the particular embodiments shown and described herein, but are equally applicable with any other suitable structure, form and configuration of components.
While exemplary embodiments of the invention have been shown and described, many variations, modifications and/or changes of the system, apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the patent applicant(s), within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of appended claims. Thus, all matter herein set forth or shown in the accompanying drawings should be interpreted as illustrative, and the scope of the invention and the appended claims should not be limited to the embodiments described and shown herein.
Number | Date | Country | |
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Parent | 12246166 | Oct 2008 | US |
Child | 13194211 | US |