The present disclosure relates to oil and gas exploration and production, and more particularly to a completion system for use in gravel packing operations.
Wells are drilled at various depths to access and produce oil, gas, minerals, and other naturally-occurring deposits from subterranean geological formations. Hydrocarbons may be produced through a wellbore traversing the subterranean formations. Gravel packing operations are commonly performed in subterranean formations to control unconsolidated particulates. A typical gravel packing operation involves placing a filtration bed containing gravel particulates near the well bore that neighbors the zone of interest. The filtration bed acts as a sort of physical barrier to the transport of unconsolidated particulates to the well bore that could be produced with the produced fluids. One common type of gravel packing operation involves placing a sand control screen in the well bore and packing the annulus between the screen and the well bore with gravel particulates of a specific size designed to prevent the passage of formation sand. The sand control screen is generally a filter assembly used to retain the gravel placed during the gravel pack operation. In addition to the use of sand control screens, gravel packing operations may involve the use of a wide variety of sand control equipment, including liners (e.g., slotted liners, perforated liners, etc.), combinations of liners and screens, and other suitable apparatus. A wide range of sizes and screen configurations are available to suit the characteristics of the gravel particulates used. Similarly, a wide range of sizes of gravel particulates are available to suit the characteristics of the unconsolidated particulates. The resulting structure presents a barrier to migrating sand from the formation while still permitting fluid flow.
The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.
In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims.
Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to”. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.
As used herein, the phrases “hydraulically coupled,” “hydraulically connected,” “in hydraulic communication,” “fluidly coupled,” “fluidly connected,” and “in fluid communication” refer to a form of coupling, connection, or communication related to fluids, and the corresponding flows or pressures associated with these fluids. In some embodiments, a hydraulic coupling, connection, or communication between two components describes components that are associated in such a way that fluid pressure may be transmitted between or among the components. Reference to a fluid coupling, connection, or communication between two components describes components that are associated in such a way that a fluid can flow between or among the components. Hydraulically coupled, connected, or communicating components may include certain arrangements where fluid does not flow between the components, but fluid pressure may nonetheless be transmitted such as via a diaphragm or piston or other means of converting applied flow or pressure to mechanical or fluid force.
While a portion of a wellbore may in some instances be formed in a substantially vertical orientation, or relatively perpendicular to a surface of the well, the wellbore may in some instances be formed in a substantially horizontal orientation, or relatively parallel to the surface of the well, the wellbore may include portions that are partially vertical (or angled relative to substantially vertical) or partially horizontal (or angled relative to substantially horizontal). In some wellbores, a portion of the wellbore may extend in a downward direction away from the surface and then back up toward the surface in an “uphill,” such as in a fish hook well. The orientation of the wellbore may be at any angle leading to and through the reservoir.
The present disclosure relates generally to completion systems that allow gravel packing while providing zonal isolation to create a plurality of distinct production zones or isolation zones. Some of the zones may be actively producing formation fluids, while others may be non-productive zones. The establishment of separate zones provides the ability to shut off some zones, thereby preventing production from these zones. Creating zones also allows for a smooth production profile when each zone is allowed to contribute. Furthermore, when an isolation zone is established in a non-producing portion of the formation, that particular zone may not be gravel packed to realize cost savings. While gravel packing operations may assist in controlling an unconsolidated zone, the process of establishing separate zones and gravel packing those zones may heighten the risk of partial or total collapse if the hydrostatic pressure within a particular zone is not able to be maintained. For this reason, it may be desirable to minimize any significant pressure differential between zones. The systems and methods described herein assist in providing pressure maintenance between the different zones, improve isolation between zones by providing the capability of simultaneous hydraulic actuation of the packers between the zones, and allow gravel packing after isolation has been established.
In the embodiments illustrated in
After drilling of the wellbore is complete and the associated drill bit and drill string are “tripped” from the wellbore 116, a work string 150 which may eventually function as a production string is lowered into the wellbore 116. The work string 150 may include sections of tubing, each of which are joined to adjacent tubing by threaded or other connection types. The work string may refer to the collection of pipes or tubes as a single component, or alternatively to the individual pipes or tubes that comprise the string. The term work string (or tubing string or production string) is not meant to be limiting in nature and may refer to any component or components that are capable of being coupled to the completion system 100 to lower or raise the completion system 100 in the wellbore 116 or to provide energy to the completion system 100 such as that provided by fluids, electrical power or signals, or mechanical motion. Mechanical motion may involve rotationally or axially manipulating portions of the work string 150. In some embodiments, the work string 150 may include a passage disposed longitudinally in the work string 150 that is capable of allowing fluid communication between the surface 108 of the well 112 and a downhole location 174.
The lowering of the work string 150 may be accomplished by a lift assembly 154 associated with a derrick 158 positioned on or adjacent to the rig 104 or offshore platform 132. The lift assembly 154 may include a hook 162, a cable 166, a traveling block (not shown), and a hoist (not shown) that cooperatively work together to lift or lower a swivel 170 that is coupled an upper end of the work string 150. The work string 150 may be raised or lowered as needed to add additional sections of tubing to the work string 150 to position the completion system 100 at the downhole location 174 in the wellbore 116.
A reservoir 178 may be positioned at the surface 108 to hold a fluid 182 for delivery to the well 112 during setting of the completion system 100. A supply line 186 is fluidly coupled between the reservoir 178 and the passage of the work string 150. A pump 190 drives the fluid 182 through the supply line 186 and the work string 150 toward the downhole location 174. As described in more detail below, the fluid 182 may also be used to carry out debris from the wellbore prior to or during the completion process. Still other uses of the fluid 182 may entail delivery of gravel or a proppant in a slurry to the downhole location 174 so that the well 112 may be gravel packed. After traveling downhole, the fluid 182 or portions thereof returns to the surface 108 by way of an annulus 194 between the work string 150 and the wellbore 116. At the surface 108, the fluid may be returned to the reservoir 178 through a return line 198. The fluid 178 may be filtered or otherwise processed prior to recirculation through the well 112.
In some embodiments, the completion assembly 204 may have a generally circular cross-sectional shape and include an inner passage 220 running longitudinally the length of the completion assembly 204. For example in these embodiments, the completion assembly 204 may include a base pipe or a series of coupled base pipes that are perforated to allow fluid communication between the annulus 208 and the inner passage 220. In other embodiments, the cross-sectional shape of the completion assembly 204 may be non-circular. The completion assembly 204 may include at least one exit port 224, the opening and closing of which is selectively controlled by a slidable or movable sleeve (not shown). The exit port 224 when opened permits fluid communication between the work string 150 and the annulus 208 by way of a crossover 226.
Positioned downhole from the exit port 224, the completion assembly 204 may further include at least one screen or slotted liner assembly 228. In some embodiments, the screen assembly 228 may comprise wire wrapped concentrically or helically around the perforated base pipe or a mesh media around the perforated base pipe such that a space between adjacent wrappings of the wire or mesh media is of a distance that allows control of particle sizes allowed to pass through the screen assembly 228. The at least one screen assembly 228 permits the passage of fluid (liquids or gases) between the annulus 208 and the inner passage 220 but prevents the passage of solids that are greater than a selected size associated with the screen assembly 228. More particularly, the screen assembly 228 is configured to prevent the passage of gravel or proppant contained in a gravel slurry from passing through slots, ports, apertures, or holes in the screen assembly 228 when the slots, ports, apertures, or holes are smaller in size than the size of the gravel particles. In some embodiments, the at least one screen assembly 228 includes a plurality of screen assemblies positioned in spaced relationship along the completion assembly 204. Regardless of whether a single or multiple screen assemblies 228 are used, each screen assembly 228 in some embodiments extends circumferentially around the completion assembly 204 such that the paths of fluid communication provided by the screen assembly are maximized. In other embodiments, the screen assemblies 228 may extend only partially around the completion assembly 204, thereby providing a more limited path of fluid communication relative to those screen assemblies 228 that circumferentially surround the completion assembly 204.
In some embodiments, the completion assembly 204 may have a float shoe 232 coupled to an end of the completion assembly 204. The float shoe 232 in the embodiment illustrated in
The system 200 includes a gravel pack packer 236 or liner hanger associated with the completion assembly 204 or alternatively with a service tool 240. More specifically, the gravel pack packer 236 is positioned uphole of each of the screen assemblies 228 and may be coupled to either the completion assembly 204, the service tool 240, or both. The gravel pack packer 236 is positionable in a set position or an unset position. In the unset position (see
The system 200 further includes at least one packer 252 associated with the completion assembly 204. In the embodiment illustrated in
When positioned in the set position, the gravel pack packer 236 and the first packer 252a define a first zone 260a in the annulus 208 between the gravel pack packer 236 and the first packer 252a. Similarly, when the first packer 252a and the second packer 252b are set, a second zone 260b is defined in the annulus 208 between the first packer 252a and the second packer 252b. In the embodiment illustrated in
The system 200 further may include a wash pipe 268 positioned within the inner passage 220 of the completion assembly 204 such that the wash pipe 268 is axially movable relative to the completion assembly 204. An annulus 270 is defined between the wash pipe 268 and the completion assembly 204. In some embodiments, the wash pipe 268 is coupled to the service tool 240 such that the wash pipe 268 is capable of being positioned downhole as the service tool 240 and gravel pack packer 236 are run into the wellbore 212. The wash pipe 268 includes at least one port and preferably a port for each packer associated with the system 200 other than the gravel pack packer 236. More specifically, in the embodiment illustrated in
The wash pipe 268 is positionable in a first position (see
Seals 284a, 284b or seal bores are coupled to the packers 252a, 252b and slick joints or seals are coupled to the wash pipe 268 to seal around the ports 272a, 272b when the wash pipe 268 is in the first position. In this position, each of the seals 284a, 284b isolate a portion of the annulus 270 between ports 272a, 272b and ports 276a, 276b, respectively. The seals 284a, 284b ensure that fluid from the wash pipe 268 when the wash pipe 268 is in the first position is limited to communication with the packers 252a, 252b and is not dispersed throughout the annulus 270.
The wash pipe 268 is positionable in a second position in which each of ports 272a, 272b is approximately aligned with a different screen assembly 228 and any perforations in the base pipe or completion assembly 204. In this position, the port 272a is approximately aligned with the screen assembly 228 between gravel pack packer 236 and first packer 252a. The port 272a in this alignment allows fluid communication between inner passage 280 and first zone 260a. The port 272b is approximately aligned with the screen assembly 228 between first packer 252a and second packer 252b. The port 272b in this alignment allows fluid communication between inner passage 280 and second zone 260b. The wash pipe 268 in the second position allows more direct fluid communication between a particular zone and the inner passage 280 of the wash pipe 268. This effectively shortens or minimizes the equivalent circulating density required to circulate fluid from the surface through the zone and then back to the surface. This shortened circulation path (compared to circulating fluid to an end of the wellbore where it could enter the wash pipe 268) prevents excessive pressure drops, which allows lower pressures to be used to gravel pack the individual zones.
It is important to note that while each zone illustrated in
As shown in
The system 200 further includes a flow control device 288 operably associated with either the wash pipe 268, the float shoe 232 or the completion assembly 204 to selectively allow or prevent fluid communication between an inner passage 280 of the wash pipe 268 and the annulus 208. In the embodiment illustrated in
When the flow control device 288 is coupled to or positioned within the wash pipe 268 as illustrated in
The system 200 further includes a gravel delivery tube 290 positioned external to the completion assembly 204. The gravel delivery tube 290 is a conduit or a series of conduits that allow gravel delivery into each of the defined zones. The gravel delivery tube 290, whether a single tube or multiple tubes, is coupled to the packers or passages associated with the packers such that the gravel delivery tube 290 is capable of providing fluid communication across zones even when the packers are in the set position. The gravel delivery tube 290 allows fluid communication between zones that are established when the packers are set. This fluid communication provides pressure equalization, or at least reduction of pressure differentials, between the zones. This communication is important as it permits maintenance of hydrostatic pressure within each zone to reduce the likelihood of wellbore collapse. Because of the presence of the seals 284a, 284b in the annulus 270 preventing fluid communication between zones when the wash pipe 268 is in the first position, the fluid communication provided between zones by the gravel delivery tube 290 may in some circumstances be the only path through which pressure equalization is provided.
In operation, and referring again to
Following the running and setting of the gravel pack packer 236 in the wellbore, the first and second packers 252a, 252b are set by positioning the wash pipe 268 in the first position as illustrated in
After the first and second packers 252a, 252b are set, the wash pipe 268 may be moved to the second position as illustrated in
The first zone 260a continues to fill with gravel or proppant, and as the first zone 260a becomes fully packed, the gravel slurry encounters more resistance to flow within the first zone 260 which results in the slurry entering the gravel delivery 290. The gravel delivery tube 290, which provided pressure equalization during the setting of the packers 252a, 252b, now provides a pathway for delivery of the gravel slurry to the second zone 260b. The second zone 260b fills in a manner similar to that described for the first zone 260a, as indicated by arrows 416. When the second zone 260b is fully packed, the third zone 260c is similarly packed, yet in the packing of this zone, the passage of clean fluid through the screen assembly 228 and into the wash pipe 268 may be through the flow control device 288 instead of a port in the wash pipe 268. It should be understood, however, that in some embodiments a port in the wash pipe similar to port 272a, 272b may be provided in fluid communication with the third zone 260c. Gravel packing in the third zone 260c, as indicated by arrows 422 continues until the third zone 260c is completely packed.
Referring to
During gravel packing and completion operations, it is important to minimize the chances of partial or total wellbore collapse. The present disclosure describes systems and methods that allow completion and gravel packing of multiple zones while providing more reliable methods of setting packers and establishing those zones. Pressure equalization is maintained across the zones as the packers are set to minimize the risks of collapse. In addition to the embodiments described above, many examples of specific combinations are within the scope of the disclosure, some of which are detailed below.
In a first example, a system for use in a wellbore includes a completion assembly extending into the wellbore such that a first annulus is created between the completion assembly and a portion of the wellbore. A gravel pack packer is adapted to seal between the completion assembly and a first, cased portion of the wellbore. At least one isolation packer is positioned downhole of the gravel pack packer. The at least one isolation packer is adapted to seal between the completion assembly and a second, cased or uncased portion of the wellbore. The gravel pack packer and the at least one isolation packer when set create at least one zone in the first annulus between the gravel pack packer and the isolation packer. The system further includes a wash pipe positioned within the completion assembly such that a second annulus is defined between the wash pipe and the completion assembly. The wash pipe includes at least one port to allow fluid communication between an interior passage of the wash pipe and the second annulus.
In the first example, the system may further include a valve that is operably associated with the wash pipe to allow or prevent fluid communication between the interior passage and the first annulus. The system may also include a gravel delivery tube positioned external to the completion assembly, the gravel delivery tube allowing gravel delivery to the zone. The system may also be configured such that the at least one isolation packer includes two or more isolation packers, each isolation packer cooperating with the gravel pack packer or another of the isolation packers to define one of the zones in the first annulus. The system may also be configured such that the at least one port of the wash pipe includes a plurality of ports and each port is associated with a different of the zones. The system may be configured such that the wash pipe is positionable in a first position to allow fluid communication between each of the plurality of ports and a corresponding packer of the plurality of packers, the wash pipe positionable in a second position to allow fluid communication each of the plurality of ports and a corresponding zone of the zones. The system may be configured such that fluid communication between each of the plurality of ports and the corresponding packer of the plurality of packers further includes fluid communication between each of the plurality of ports and a corresponding hydraulic port on each corresponding packer to deliver fluid to the corresponding packer such that a sealing element of the corresponding packer is set. The system may be configured such that the valve is remotely activated. Each of the preceding configurations and elements of the system of the first example optionally may be utilized with the system, and the various configurations and elements may be combined with other described configurations and elements in any particular combination.
In a second example, a system for use in a wellbore includes a completion assembly having a gravel pack packer. The completion assembly is positioned in the wellbore such that an annulus is created between the completion assembly and a portion of the wellbore. A first packer is associated with the completion assembly and is positioned downhole of the gravel pack packer. The gravel pack packer and the first packer define a first zone in the annulus between the gravel pack packer and the first packer. The system includes a second packer associated with the completion assembly and positioned downhole of the first packer, the first packer and the second packer defining a second zone in the annulus between the first packer and the second packer. A wash pipe is positioned within the completion assembly and includes at least two ports. The wash pipe is positionable in a first position to allow fluid communication between the first port and the first packer and the second port and the second packer. The wash pipe is positionable in a second position to allow fluid communication between the first port and the first zone and the second port and the second zone. The system further includes a gravel delivery tube positioned external to the completion assembly, the gravel delivery tube allowing gravel delivery into at least one of the first zone and the second zone.
In the second example, the system may be configured such that the wash pipe in the second position allows pressure equalization between the first zone and the second zone. The system may be configured such that the first packer and the second packer are hydraulic packers. The system may be configured such that fluid communication between the first port and the first packer further comprises fluid communication between the first port and a hydraulic port of the first packer to deliver fluid to the first packer such that a sealing element of the first packer is set. The system may be configured such that fluid communication between the first port and the first packer further comprises fluid communication between the first port and a hydraulic port of the first packer to deliver fluid to the first packer such that a sealing element of the first packer is set. The system may further include a valve operably associated with the wash pipe or the completion assembly to allow or prevent fluid communication between an interior passage of the wash pipe and the annulus. The system may be configured such that a portion of the completion assembly in each of the first zone and the second zone includes a port to allow fluid communication between an interior of the completion assembly and the annulus. The system may further include a screen assembly to prevent gravel of a selected size in each zone from entering the interior of the completion assembly. Each of the preceding configurations and elements of the system of the second example optionally may be utilized with the system, and the various configurations and elements may be combined with other described configurations and elements in any particular combination.
In a third example, a method of gravel packing a wellbore includes establishing at least two zones in the wellbore, flowing a gravel slurry to at least one of the zones to gravel pack the at least one zone, and reducing an equivalent circulation density of fluid from the gravel slurry returning to a surface of the wellbore.
In the third example, the method may further include providing fluid communication between the at least two zones to reduce a pressure differential between the at least two zones. The method may be configured such that establishing at least two zones further includes setting a plurality of packers to seal between a completion assembly and a portion of the wellbore. The method may be configured such that each of the at least two zones is defined between two of the plurality of packers in an annulus between the completion assembly and the portion of the wellbore. The method may further include providing a wash pipe within the completion assembly, wherein establishing at least two zones further comprises flowing fluid through the wash pipe to hydraulically set the plurality of packers. The method may be configured such that flowing a gravel slurry to at least one of the zones further includes flowing the gravel slurry to a first of the at least two zones and following gravel packing of the first, flowing the gravel slurry to a second of the at least two zones. The method may be configured such that providing fluid communication between the at least two zones further includes screening the flow of fluid between the at least two zones to prevent gravel in the gravel slurry from moving between the at least two zones. The method may further include providing a wash pipe within the completion assembly, wherein providing fluid communication between the at least two zones further includes aligning ports in the wash pipe with the at least two zones such that fluid communication between the at least two zones is provided through the wash pipe. Each of the preceding configurations and elements of the method of the third example optionally may be utilized with the method, and the various configurations and elements may be combined with other described configurations and elements in any particular combination.
It should be apparent from the foregoing that embodiments of an invention having significant advantages have been provided. While the embodiments are shown in only a few forms, the embodiments are not limited but are susceptible to various changes and modifications without departing from the spirit thereof.
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PCT/US2015/034555 | 6/5/2015 | WO | 00 |
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WO2016/195720 | 12/8/2016 | WO | A |
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