U.S. patent application number 10/097056 was filed with the patent office on 2002-10-17 for intelligent well sand control.
Invention is credited to Bussear, Terry, Corbett, Thomas G..
Application Number | 20020148610 10/097056 |
Document ID | / |
Family ID | 23073721 |
Filed Date | 2002-10-17 |
United States Patent
Application |
20020148610 |
Kind Code |
A1 |
Bussear, Terry ; et
al. |
October 17, 2002 |
Intelligent well sand control
Abstract
A sand control assembly having individual single zone flow
control for a multizone hydrocarbon well having remote control
capability. Flow control in individual zones and superior packing
are achieved.
Inventors: |
Bussear, Terry; (Round Rock,
TX) ; Corbett, Thomas G.; (Willis, TX) |
Correspondence
Address: |
CANTOR COLBURN LLP
55 Griffin Road South
Bloomfield
CT
06002
US
|
Family ID: |
23073721 |
Appl. No.: |
10/097056 |
Filed: |
March 12, 2002 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60280587 |
Apr 2, 2001 |
|
|
|
Current U.S.
Class: |
166/278 ;
166/51 |
Current CPC
Class: |
E21B 43/045
20130101 |
Class at
Publication: |
166/278 ;
166/51 |
International
Class: |
E21B 043/04 |
Claims
What is claimed:
1. A sand control assembly in a well comprising: a screen; a valve
disposed downhole of said screen; a packer disposed uphole of said
screen; a sump packer disposed downhole of said valve.
2. A sand control assembly as claimed in claim 1 wherein said
screen further includes blank tubing disposed radially inwardly of
said screen and in spaced relationship with said screen to define
an annular flow area between said tubing and said screen.
3. A sand control assembly as claimed in claim 2 wherein said
annular flow area is fluidly connected to said valve.
4. A sand control assembly as claimed in claim 3 wherein a fluid
flowing in said annular flow area is conveyable through said valve
to an I.D. of said assembly.
5. A sand control assembly as claimed in claim 1 wherein said valve
is remotely controlled.
6. A sand control assembly as claimed in claim 1 wherein said
assembly further comprises a flow control device located between
said packer and said screen.
7. A sand control assembly as claimed in claim 6 wherein said flow
control device is receptive to through flow of a slurry material
from a crossover tool disposed thereat.
8. A sand control assembly as claimed in claim 1 wherein said
gravel pack assembly includes a plurality of said screen, said
valve and said packer.
9. A sand control assembly as claimed in claim 6 wherein said
gravel pack assembly includes a plurality of said screen, said
valve and said packer.
10. A sand control assembly as claimed in claim 1 wherein said
valve is an IPR valve.
11. A sand control assembly as claimed in claim 10 wherein said IPR
valve includes at least one sensor.
12. A sand control assembly in a well comprising: installing the
gravel pack assembly of claim 1; opening said valve; and producing
the well.
13. A method for sand control comprising: installing the sand
control assembly of claim 6; running a crossover tool into the well
and opening said flow control device; opening said valve; pumping a
slurry into said sand control assembly through said flow control
device and back to a remote location through said valve.
14. A method for sand control as claimed in claim 13 wherein said
method further comprises closing said flow control device with said
crossover tool.
15. A method for sand control as claimed in claim 13 wherein said
method further comprises closing said valve remotely.
16. A method for sand control as claimed in claim 13 wherein said
method includes sensing a wellbore parameter related to sand
control.
17. A method for sand control as claimed in claim 13 wherein said
method further includes sensing pressure, at least one of upstream
of said valve and downstream of said valve.
18. A method for sand control as claimed in claim 17 wherein said
method further includes sensing pressure upstream of said screen.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of an earlier filing
date from U.S. Provisional Application Serial No. 60/280,587 filed
Apr. 2, 2001, the entire disclosure of which is incorporated herein
by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The disclosure relates to oil field gravel pack systems and
methods for their use. More particularly, the disclosure relates to
multiple sand control assemblies with single zone control.
[0004] 2. Prior Art
[0005] Sand control apparatus, systems and methods have been an
important part of wells for hydrocarbon production for an extended
period and are used to support boreholes in unconsolidated
formations as well as to cause particulate matter (such as sand)
entrained in production fluid to bridge at the sand control
assembly and thus be excluded from the tubing of the well.
Unfortunately prior art sand control assemblies, in order to obtain
individual zone control employ an inner assembly which reduces the
I.D. of the string available for other purposes. Without the inner
assembly individual zonal control is not possible.
SUMMARY
[0006] Multizone sand control assemblies with flow control for
individual zones can be achieved while maintaining a full bore I.D.
of the sand control assembly. The sand control assemblies that make
the realization of these benefit possible comprise individual
components that are commercially available but which have not
heretofore been combined. The effect of the combination as taught
herein is synergistic and produces results of significant benefit
to the art such as the mentioned individual control whether the
control is for production fluids or remediation fluids; and in one
embodiment produces superior gravel packing. The assembly includes
a string of spaced apart packers, with a sump packer at a most
downhole location for the string. The packers are interspersed by
gravel pack screen sections and sliding sleeves (the number of
sleeves depends upon the embodiment). In addition, a blank pipe
section is located radially inwardly of each screen section in both
of the discussed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Referring now to the drawings wherein like elements are
numbered alike in the several Figures:
[0008] FIGS. 1 and 2 is an elongated view in quarter section of a
gravel pack flow control assembly; and
[0009] FIGS. 3 and 4 is an alternate elongated view in quarter
section of a gravel pack flow control assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Two embodiments are disclosed herein which provide control
in a multizone sand control assembly. Control is with respect to
fluids flowing into the well through individual or selective groups
of zones and for sealing off selected zones during remediation
treatment to avoid damaging or contaminating zones not in need of
remediation. Consequently, such control also alleviates the
unnecessary loss of expensive remediation fluids which in some
prior art systems are needlessly and profitlessly lost into the
formation. In addition, for one of the embodiments discussed
herein, the control gained by the particular assemblies discussed
enhances an active gravel packing procedure by alleviating bridging
otherwise caused by rapid "dehydration" of the gravel pack slurry
(usually gravel and a liquid carrier) to the formation. The use of
either of the assemblies described herein preferably follows
conventional perforating and fracturing operations. In each
embodiment, recirculation of excess proppant out of the well after
fracturing is preferred.
[0011] In a first embodiment, referring to FIGS. 1 and 2, a
multiple zone sand control assembly 10 is illustrated with three
zones 12a, 12b and 12c. A sump packer 14 is located at a downhole
end of the assembly 10 as illustrated. Sump packer 14, in one
embodiment, is installed in the well in a distinct run on
preferably wireline to facilitate deployment in a desired location.
Alternatively, sump packer 14 could be made a part of assembly 10.
Assembly 10 is otherwise installed as a single assembly in one run
in the hole. Where sump pump 14 is installed in a separate run,
assembly 10 is stabbed into sump packer 14 with locator tubing seal
assembly 16. Preferably assembly 10 is constructed at a surface
location with spacing sufficient to locate a plurality of screens
included therein proximate perforations 18 in casing 20 which were
created in the perforating operation.
[0012] Locator tubing seal assembly 16 is connected to a valve 22,
preferably an intelligent production regulator (IPR) valve
commercially available from Baker Oil Tools, Houston, Texas. IPR
valves preferably comprise a valve for regulating flow of a fluid
in addition to pressure sensors. One pressure sensor is located
upstream of the valve and one pressure sensor is located downstream
of the valve. IPR valve 22 is connected through a shroud 24 and
sliding sleeve 26 to a bypass packoff sub 28 having a flow conduit
30 therein which communicates with annular space 32 between shroud
24 and sleeve 26. Radially inwardly and sealed to sub 28 is tubing
34. Tubing 34 is preferably sealed to sub 28 with one or more
O-rings 36. Connected at an uphole end of sub 28 is crossover sub
38 having pin and box threads at downhole and uphole ends thereof,
respectively.
[0013] Crossover sub 38 is connected at its uphole end to a screen
40. It should be noted that between screen 40 and tubing 34 is
defined an annular flow area 42, which area is fluidly connected to
conduit 30 in sub 28 and thereby to annular space 32. Fluid flowing
in the spaces defined is conveyable to an I.D. 43 of the pack
assembly 10 through one or more flow ports 44 controlled by IPR
valve 22 via sleeve 46. It should further be noted that such flow
may also be conveyed to the I.D. 43 of pack assembly 10 through one
or more ports 48 in sliding sleeve 26 controlled by manually
operable sleeve 50 which generally would be used in the event IPR
valve 22 did not function as intended.
[0014] Referring back to screen 40 and tubing 34, both elements are
preferably connected at an uphole end thereof to double pin sub 52
which in turn is connected to a blank pipe section 54. Blank pipe
section 54 is connected to a retrievable packer 56.
[0015] Each of the ensuing uphole portions of sand control assembly
10 bear similar numerals (one hundred and two hundred series of the
same numbers) since the individual components illustrated are
identical to those described above.
[0016] A preferred concise procedure for installation of the
above-discussed embodiment is as follows:
[0017] 1. Set sump packer below planned lower zone
perforations.
[0018] 2. Perforate lower zone.
[0019] 3. Perform hydraulic fracture treatment in lower zone.
[0020] 4. Leave sand plug across lower zone and perforate middle
zone.
[0021] 5. Perform hydraulic fracture treatment in middle zone.
[0022] 6. Leave sand plug across middle zone and perforate upper
zone.
[0023] 7. Perform hydraulic fracture treatment in upper zone.
[0024] 8. Wash sand out of casing using PERFFLOW pills as required
to control fluid loss.
[0025] 9. Run isolation packers, screens and IPR valves as
illustrated with valves closed.
[0026] 10. Stab into sump packer and pressure tubing to set
isolation packers.
[0027] 11. Open IPR valves and bring well on production (frac sand
will flow back and fill annulus between screen and casing).
[0028] Assembly 10, having been installed in a well casing 20 after
a fracturing and a recirculation cleanout procedure, is intended to
receive a natural gravel pack. As one of skill in the art will
recognize, many thousands of pounds of proppant (usually sand or
gravel) is pumped into perforation zones in a well for the
fracturing operation. Thus, far more than a sufficient quantity of
proppant exists adjacent perforations 18 and in perforations 18
after the recirculating clean out of the well to satisfy the need
for proppants in a "natural gravel pack" operation. Once assembly
10 is set, IPR valve 22 is opened and the well is allowed to flow.
By the action of this flow, proppants left in the perfs 18 and in
the vicinity thereof and which are not propping fractures open are
driven toward screen 40 where they are "dehydrated" against the
screen while wellbore fluids pass therethrough. Proppants continue
to be drawn to the screen and in the direction of gravity to the
next packer until the annular space 58 between packer 56 and sump
packer 14 is filled with proppant. The wellbore fluid flowing
through screen 40 is conveyed via annular flow area 42 through
conduit 30 to annular space 32 and through port 44, preferentially,
or port 48 into assembly I.D. 43 and to an uphole location. This is
the condition in which the zone will operate during normal well
production, however in order to facilitate natural gravel packing
of the other zones 12b, 12c (two illustrated but not so limited),
IPR valve 22 is preferably closed. The process for zone 12b begins
as did the process for zone 12a with the opening of an IPR valve
122 (one hundred series of same numerals). Upon completion of the
natural gravel packing operation of zone 12b a similar process will
preferably occur in zone 12c and so on for any remaining zones.
[0029] Subsequent to the natural gravel packing operation, one or
more of the IPR valves 22, 122, 222 may be opened to produce the
well. It should be noted that each of the IPR valves is preferably
addressable and operable from a remote location.
[0030] Facilitating remote location actuation is preferably a TEC
(tubing encapsulated conductor) 60 extending from the remote
location to each IPR valve. Of course it will be appreciated that
other means of communicating with the IPR valves remotely can be
substituted such as but not limited to fiber optic conductors
hydraulic line, etc.
[0031] The assembly 10 affords control in each zone of a multizonal
sand control assembly individually, collectively or in any
combination to promote or hinder production from that zone.
Additionally, the capability of remotely controlling each zone
allows for controlling the loss of expensive fluids intended to
have an effect on one or more zones but not others. Moreover,
remote control allows for protection of the perforations from
harmful remediation activities needed in one or more but not all
zones. Furthermore, the embodiment maintains a full bore I.D. of
the assembly 10 which facilitates both higher production rate
capability and allows larger tools or strings to pass through the
assembly 10 to or from more downhole locations.
[0032] In another embodiment, referring to FIGS. 3 and 4, a frac
and pack assembly 310 is illustrated. Since the great majority of
components of assembly 310 are common to the embodiment of FIGS. 1
and 2, the three hundred, four hundred and five hundred series
numerals thereon will suffice in combination with the foregoing
explanation to explain the portions of the assembly not
specifically addressed in the paragraphs subsequent hereto.
[0033] The embodiments of FIGS. 3 and 4 differ from the foregoing
embodiment in areas bounded by double pin sub 352 and blank pipe
354. The distinction is the interconnection of additional blank
pipe 362 and sliding sleeve 364 having port 366 and manually
actuatable sleeve 368. Sleeve 368 is actuable by a conventional
crossover tool (not shown).
[0034] In keeping with the foregoing information, the following is
a concise list of procedures for installing the second embodiment
discussed herein. Operations relevant to the assembly 310 are
further discussed hereunder. The concise procedure is as
follows:
[0035] 1. Set sump packer below planned lower zone
perforations.
[0036] 2. Perforate lower zone.
[0037] 3. Perform hydraulic fracture treatment in lower zone.
[0038] 4. Leave sand plug across lower zone and perforate middle
zone.
[0039] 5. Perform hydraulic fracture treatment in middle zone.
[0040] 6. Leave sand plug across middle zone and perforate upper
zone.
[0041] 7. Perform hydraulic fracture treatment in upper zone.
[0042] 8. Wash sand out of casing using PERFFLOW pills as required
to control fluid loss.
[0043] 9. Run isolation packers, screens and IPR valves as
illustrated with valves closed.
[0044] 10. Stab into sump packer and pressure tubing to set
isolation packers.
[0045] 11. Run crossover tool with selective shifting tool on
coiled tubing and open lower CMD sliding sleeve.
[0046] 12. Position crossover tool across lower CMD sliding
sleeve.
[0047] 13. Open lower IPR valve and circulate gravel pack into
screen/casing annulus until screenout.
[0048] 14. Pick-up crossover tool and circulate out excess
gravel.
[0049] 15. Pull out of hole with crossover tool and close lower CMD
sliding sleeve and IPR.
[0050] 16. Run crossover tool with selective shifting tool on
coiled tubing and open middle CMD sliding sleeve.
[0051] 17. Position crossover tool across middle CMD sliding
sleeve.
[0052] 18. Open middle IPR valve and circulate gravel pack into
screen/casing annulus until screenout.
[0053] 19. Pick-up crossover tool and circulate out excess
gravel.
[0054] 20. Pull out of hole with crossover tool and close middle
CMD sliding sleeve and IPR.
[0055] 21. Run crossover tool with selective shifting tool on
coiled tubing and open upper CMD sliding sleeve.
[0056] 22. Position crossover tool across upper CMD sliding
sleeve.
[0057] 23. Open upper IPR valve and circulate gravel pack into
screen/casing annulus until screenout.
[0058] 24. Pick-up crossover tool and circulate out excess
gravel.
[0059] 25. Pull out of hole with crossover tool and close upper CMD
sliding sleeve and IPR.
[0060] 26. Open IPR valves and bring well on production.
[0061] Assembly 310, like assembly 10, is run in the hole and set
subsequent to perforating and fracturing operations as well as
recirculating cleanout of proppants left in the I.D. of casing 20.
The sand control operation in this embodiment however includes an
active gravel packing operation in that a gravel slurry is directed
into annulus 58 through the crossover tool having had its discharge
port (not shown) aligned with port 366 in sliding sleeve 364. IPR
valve 322 is opened and gravel laden slurry is propagated toward
screen 340 through port 366 from the crossover tool (not shown).
Upon reaching screen 340 and particularly starting at a downhole
end of screen 340, gravel or other sand control material is
"dehydrated" due to the carrier fluid being drawn off through
screen 340 to annular flow area 358, through fluid conduit 330 to
annular space 332 through port 344 preferentially or port 348
secondarily to assembly 310, I.D. 343 for delivery back to the
crossover sub and to an uphole location. Gravel packing continues
until a pressure drop downhole of the screen or pressure spike
uphole of the screen is detected. Pressure conditions are
detectable by the IPR valve using sensors as indicated above and/or
by an additional sensor located preferably uphole of the sliding
sleeve 364 and downhole of the zones uphole defining packer 356,
456 and 556. A sensor is schematically illustrated in FIGS. 3 and 4
and is numbered 370, 470 and 570 in the respective zones. Upon
detected pressure change, pumping of the slurry is halted. The
following action of pulling the crossover tool uphole to the next
zone closes sleeve 368. IPR valve 322 is also preferably closed to
completely seal off zone 312 while packing operations proceed in
zones 312b and 312c sequentially. It should be noted that this
embodiment, as in the foregoing embodiment, maintains a full bore
I.D. of the gravel pack assembly 310 which allows for higher flow
rates of sand control pack carrying fluid back to an uphole
location than was possible in the prior art due to a restricted
diameter return flow tube. This creates a better gravel pack by
avoiding potential bridging caused by slurry flowing out to the
reservoir faster than it could move up the return. In addition this
embodiment is endowed with the beneficial features of the foregoing
embodiment including remote control.
[0062] While preferred embodiments of the invention have been shown
and described, various modifications and substitutions may be made
thereto without departing from the spirit and scope of the
invention. Accordingly, it is to be understood that the present
invention has been described by way of illustration and not
limitation.
* * * * *