U.S. patent application number 10/280400 was filed with the patent office on 2003-05-01 for completion system, apparatus, and method.
Invention is credited to Bixenman, Patrick W., Orzechowski, Diana, Pramann, James A. II.
Application Number | 20030079878 10/280400 |
Document ID | / |
Family ID | 23329338 |
Filed Date | 2003-05-01 |
United States Patent
Application |
20030079878 |
Kind Code |
A1 |
Pramann, James A. II ; et
al. |
May 1, 2003 |
Completion system, apparatus, and method
Abstract
A well completion has an inner completion with a control valve
surrounded by spaced seals that is positioned in an outer
completion, such as a sand control completion. A control line
extends from the valve through one of the seals. It is emphasized
that this abstract is provided to comply with the rules requiring
an abstract which will allow a searcher or other reader to quickly
ascertain the subject matter of the technical disclosure. It is
submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. 37 CFR
1.72(b).
Inventors: |
Pramann, James A. II; (Sugar
Land, TX) ; Orzechowski, Diana; (Pearland, TX)
; Bixenman, Patrick W.; (Bartlesville, OK) |
Correspondence
Address: |
Schlumberger Technology Corporation
Schlumberger Reservoir Completions
14910 Airline Road
P.O. Box 1590
Rosharon
TX
77583-1590
US
|
Family ID: |
23329338 |
Appl. No.: |
10/280400 |
Filed: |
October 25, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60339512 |
Oct 26, 2001 |
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|
Current U.S.
Class: |
166/278 ;
166/242.3; 166/381 |
Current CPC
Class: |
E21B 43/14 20130101;
E21B 34/10 20130101 |
Class at
Publication: |
166/278 ;
166/381; 166/242.3 |
International
Class: |
E21B 043/04; E21B
017/00; E21B 023/00 |
Claims
We claim:
1. A system for completing a well, comprising: a sand control
device; a first inner polished bore receptacle above the sand
control device; a second inner polished bore receptacle below the
sand control device; a completion positioned inside the sand
control device having a first seal assembly sealingly mating with
the first inner polished bore receptacle and having a second seal
assembly sealingly mating with the second inner polished bore
receptacle; a valve of the completion positioned between the first
and second seal assemblies; and a control line extending from the
valve and through the first seal assembly.
2. The system of claim 1, wherein the sand control device is a sand
screen.
3. The system of claim 1, wherein the sand control device is a
slotted liner.
4. The system of claim 1, further comprising an intelligent
completions device in the completion.
5. The system of claim 1, wherein the control line is a fiber optic
line and the fiber optic line that provides functionality.
6. The system of claim 1, wherein: the first polished bore
receptacle has a control line passageway therethrough; and the
control line extends through the control line passageway.
7. The system of claim 1, further comprising: the first polished
bore receptacle has a primary production passageway that is
eccentric with respect to a centerline of the first polished bore
receptacle.
8. The system of claim 1, further comprising a locator device.
9. The system of claim 1, further comprising: a second sand control
device; the second first polished bore receptacle is positioned
between the sand control device and the second control device.
10. The system of claim 9, further comprising: a third polished
bore receptacle positioned below the second sand control device;
the completion having a third seal assembly sealingly mating with
the third inner polished bore receptacle.
11. The system of claim 9, further comprising: a fourth polished
bore receptacle positioned between the sand control device and the
second sand control device; and the completion having a fourth seal
assembly sealingly mating with the fourth inner polished bore
receptacle.
12. The system of claim 9, further comprising: a second valve of
the completion positioned below the second seal assembly; and a
control line extending from the valve and through the first seal
assembly and the second seal assembly.
13. The system of claim 9, wherein the second sand control device
is a sand screen.
14. The system of claim 9, wherein the second sand control device
is a slotted liner.
15. The system of claim 1, further comprising: a circulating valve;
one of the first polished bore receptacle and the second polished
bore receptacle is positioned between the circulating valve and the
sand control device.
16. The system of claim 1, further comprising a gravel pack.
17. A method for completing a well, comprising: completing a well
so as to define an area of fluid ingress into a completion;
positioning a conduit within the completion; sealing between the
conduit and the completion above and below the area of fluid
ingress with spaced seals; controlling the flow into the conduit
with a valve; and routing a control line from the valve through one
of the seals.
18. The method of claim 17, further comprising providing a screen
at the area of fluid ingress.
19. The method of claim 17, further comprising gravel packing the
well.
20. The method of claim 17, further comprising: completing the well
to define a plurality of areas of fluid ingress; isolating the
areas of fluid ingress from one another by sealing between the
conduit and the completion above and below the areas of fluid
ingress with spaced seals; independently controlling the flow into
the conduit from each of the areas of fluid ingress.
21. The method of claim 17, wherein the sealing comprises inserting
a seal assembly attached to the conduit into a mating polished bore
receptacle of the completion.
22. The method of claim 17, further comprising measuring a
parameter between the spaced seals.
23. The method of claim 17, further comprising engaging a locator
device and ensuring proper alignment between the completion and the
conduit.
24. The method of claim 17, further comprising isolating a
circulating valve of the completion with one of the spaced
seals.
25. A system for controlling flow in a well having a sand control
completion therein, comprising: an inner completion comprising a
tubing, a first seal, a second seal, and a valve between the first
seal and the second seal; the first seal positioned and adapted to
seal above a sand screen of the sand control completion; the second
seal positioned and adapted to seal below the sand screen; a
control line extending from the valve and through the first
seal.
26. The system of claim 25, further comprising an intelligent
completions device of the inner completion.
27. The system of claim 25, wherein: the first seal has a control
line passageway therethrough; and the control line extends through
the control line passageway.
28. The system of claim 25, further comprising: the second seal is
positioned to seal between two sand screens of the sand control
completion.
29. The system of claim 28, further comprising: a third seal of the
inner completion is positioned and adapted to seal below a second
sand screen of the sand control completion.
30. The system of claim 28, further comprising a fourth seal of the
inner completion positioned and adapted to seal between the two
sand screens.
31. The system of claim 28, further comprising a second valve of
the inner completion positioned below the second seal.
32. The system of claim 25, further comprising: one of the first
seal and the second seal is positioned to seal between a
circulating valve of the sand control completion and the
screen.
33. A method of controlling flow in a well having a sand control
completion therein, comprising: running an inner completion into
the sand control completion; sealing between the inner completion
and the sand control completion above a sand screen of the sand
control completion to create an isolation zone; controlling a valve
of the inner completion to selectively control the flow into the
inner completion, the valve positioned in the isolation zone.
34. The method of claim 33, further comprising running a control
line from the valve through a seal used to seal between the inner
completion and the sand control completion.
35. The method of claim 33, further comprising isolating multiple
zones of the sand control completion with the inner completion;
controlling the flow from each of the zones into the inner
completion using valves controlled from the surface.
36. The method of claim 33, further comprising measuring a
parameter of the isolated zone using an intelligent completions
device of the inner completion.
37. The method of claim 33, further comprising isolating a
circulating valve of the sand control completion with the sealing
between the inner completion and the sand control completion.
38. The method of claim 33, further comprising sealing between the
inner completion and the sand control completion below the sand
screen of the sand control completion.
39. A seal assembly, comprising: a body; an eccentric passageway
through the body defining a relatively thick portion of the wall; a
control line passageway in the thick portion.
40. A system for controlling flow in a well having a sand control
completion therein, comprising: an inner completion positioned in
the sand control completion; means for sealing between the inner
completion and the sand control completion above a sand screen of
the sand control completion to create an isolation zone; means for
selectively controlling a flow into the inner completion in the
isolation zone.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The following is also based upon and claims priority to U.S.
provisional application serial No. 60/339,512, filed Oct. 26,
2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to the field of completions.
More specifically, the invention relates to a device and method for
a completing a well using an inner completion string.
[0004] 2. Related Art
[0005] Oil companies are continually improving their recovery
systems to produce oil and gas more efficiently and economically
from sources that are continually more difficult to exploit,
without significantly increasing the cost to the consumer. One
relatively recent development to increase production is the use of
intelligent completions. Intelligent completions generally include
downhole monitoring devices and control devices that are remotely
actuatable from the surface. Intelligent completions as well as
other types of completions require the use of control lines (e.g.,
electrical, fiber optic, and hydraulic lines and combinations
thereof) that extend through the well to equipment positioned
therein. Routing of the control lines is often an issue in a number
of completions. For example, in sand control completions, the
control line is typically run with the sand screens that are then
gravel packed. When the production string is run and stabbed into
the polished bore receptacle (PBR) of the sand screen completion,
the control lines installed with the sand control completion must
be connected to the surface. This connection is generally made with
a wet connect which are generally considered undesirable.
[0006] Additionally, once the sand control completion is gravel
packed in the well, it is very difficult or impossible to remove.
Accordingly, the equipment installed in the sand control completion
generally cannot be replaced easily.
[0007] In sand control completions having multiple zones, it is
desirable to separate the production from and injection into the
various zones.
[0008] Also, there is a need for remedial completions inside
preexisting completions or as a redundant option for new
completions.
SUMMARY
[0009] In general, according to one embodiment, the present
invention provides a sand control completion in which an inner
completion is run into a sand screen. The inner completion
comprises the flow control equipment as well as the control line to
the surface. In another embodiment, the present invention comprises
an isolation seal assembly having a control line passageway
therethrough.
[0010] Other features and embodiments will become apparent from the
following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The manner in which these objectives and other desirable
characteristics can be obtained is explained in the following
description and attached drawings in which:
[0012] FIG. 1 illustrates an embodiment of the present invention
showing multiple zones.
[0013] FIG. 2 illustrations a blown-up portion of FIG. 1 of the
present invention.
[0014] FIG. 3 illustrates an alternative embodiment of the present
invention.
[0015] FIG. 4 is an end view of an embodiment of a seal assembly of
the present invention.
[0016] FIG. 5 is a side, cross sectional view of an embodiment of a
seal assembly of the present invention.
[0017] FIG. 6 illustrates an alternative embodiment of the present
invention.
[0018] FIG. 7 illustrates an alternative embodiment in which a PBR
is positioned between a screen and a circulating valve.
[0019] It is to be noted, however, that the appended drawings
illustrate only typical embodiments of this invention and are
therefore not to be considered limiting of its scope, for the
invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those skilled in the art that the present
invention may be practiced without these details and that numerous
variations or modifications from the described embodiments may be
possible.
[0021] Although the figures show the invention used in a multi-zone
completion, the present invention may be used in a single zone
completion. Further, the present invention may be employed in some
of the zones (e.g., one of the zones) of a multi-zone completion if
desired.
[0022] Referring to FIG. 1, a well 2 having a casing 4 therein
extends through a plurality of perforated zones 6. Each zone is
completed with a sand screen completion 10. The sand screen
completion 10 may be as shown or use other sand screen completion
methodologies and equipment. In the embodiment shown, the sand
screen completion 10 comprises a sump packer 12 having a polished
bore receptacle (PBR) 14 therein. Note that the PBR 30 may be
incorporated into a separate piece of the completion. However, it
is generally described herein as attached to or part of the packer
for ease of discussion. The sump packer 12 is placed and set in the
well below a zone 6. A sand screen assembly 16, comprising a sand
screen 18 and a seal assembly 20 at its lower end, is attached to
the lower end of a packer 22. The sand screen assembly 16 is
positioned in the well with the seal assembly 20 in sealing
engagement with the PBR 14 of the sump packer 12. The packer 22 of
the sand screen assembly 16, which also has a PBR 14 therein, is
set, thereby isolating the associated zone 6 between the packers
12, 22.
[0023] If desired, a service string (not shown) is run into the
well and the zone 6 is gravel packed by any desired method. U.S.
Pat. No. 6,220,353, issued Apr. 24, 2001, discusses a gravel
packing procedure and associated tools and is hereby incorporated
by reference. Other methods of gravel packing the zone 6 are known
and may be used with the present invention.
[0024] If the well has multiple zones they may also be completed as
described above. For example, the seal assembly 20 of a second sand
screen assembly 16 stabs into the PBR 14 of the previously
installed sand screen assembly 16. Once the packer 22 of the second
sand screen assembly 16 is set, the packers 22 of the two sand
screen assemblies 16 isolate the additional, upper zone. The second
zone may then be gravel packed. Additional zones may be completed
in like manner.
[0025] In an alternative embodiment, a multizone well sand screen
completion 10 may be completed as described in U.S. patent
application Ser. No. 09/631,859, filed Aug. 3, 2000 which is hereby
incorporated herein by reference. In this embodiment, the gravel
pack is accomplished through-tubing so that all of the hardware for
the sand screen completion 10 for all zones may be installed before
the gravel pack operation is performed. Similarly, a multizone well
sand screen completion 10 may be completed as described in U.S.
Pat. No. 6,311,772, issued Nov. 6, 2001 which is hereby
incorporated herein by reference or may be completed in other known
manners.
[0026] Above and below each of the sand screens 18 is an inner PBR
30. Note that, rather than providing inner PBRs 30 above and below
each sand screen 18 in each sand screen assembly 16 of a multi-zone
well 2, each sand screen assembly 16 may have one inner PBR 30
below the sand screen 18. However, the overall completion has at
least one PBR 30 between the zones of the well. The inner PBR 30 of
the two sand screen assemblies 16 providing isolation of the
lowermost of the two sand screen assemblies 16. The uppermost sand
screen assembly 16 of the sand control completion 10 would then
have an inner PBR 30 above its sand screen 18 to provide for
isolation of that uppermost zone. However, the use of an upper and
lower inner PBR 30 in each sand screen assembly 16 provides a
redundant seal and a more reliable system. Generally, the sand
screen assemblies 16 have a circulating valve 32 (FIG. 7) above the
sand screen 18 that is used during gravel packing. The upper inner
PBR 30 provides additional reliability in the case of a leak in the
circulating valve. If a PBR 30 is placed between the circulating
valve and the sand screen 18, the circulating valve is isolated
from the production by the PBR 30 once a completion 40 (discussed
below) is put into place.
[0027] A completion 40 run into the well 2 is inserted into the
sand screen completion 10. Seal assemblies 42 of the completion 40
mate with the inner PBRs 30 to isolate the associated zone(s). Flow
entering the annulus formed between the sand screen 18 and the
completion 40 is controlled with valves 44 in the completion 40.
The seal assemblies 42 and inner PBRs 30 provide for the control of
flow through the valves 44. Control lines 46 extend along the
completion 40 through the seal assemblies 42 to provide power and
telemetry to the valves 44 or other equipment in the well 2.
[0028] In the embodiment shown, the completion 40 comprises a
production tubing 50 (or conduit) extending to the surface of the
well 2. A safety valve 52 and a packer 54 are positioned in the
well 2 about the production tubing 50 above the sand control
completion 10. A seal assembly 42 attached to the production tubing
50 mates with the uppermost inner PBR 30. Below the seal assembly
42, is a control valve 44. A seal assembly 42 below the control
valve 44 mates with the inner PBR 30 below the sand screen 18 of
the associated zone 6 to isolate the zone. Together, the seal
assemblies 42 above and below a control valve 44 and the equipment
therebetween are referred to collectively as an isolation assembly
56. FIG. 2 illustrates one isolation assembly 56. Although
primarily described herein as isolating a single zone 6, an
isolation assembly 56 may bridge more than one zone 6 if
desired.
[0029] A control line 46 extends from the valve 44 and through the
seal assembly 42 to a position above the sand control completion
10. Generally, the control line 46 extends to the surface, but may
extend to a downhole controller, power supply, or telemetry
equipment, such as an inductive coupler or acoustic transmitter.
Examples of control lines 46 are electrical, hydraulic, fiber optic
and combinations of thereof. Other equipment may also be provided
in the isolation assembly 56 or isolated portion that requires a
control line 46 connected thereto. For example, the completion 40
may have intelligent completions devices such as gauges, sensors,
valves, sampling devices, temperature sensors, pressure sensors,
flow rate measurement devices, oil/water/gas ratio measurement
devices, scale detectors, actuators, locks, release mechanisms,
equipment sensors (e.g., vibration sensors), sand detection
sensors, water detection sensors, data recorders, viscosity
sensors, density sensors, bubble point sensors, composition
sensors, resistivity array devices and sensors, acoustic devices
and sensors, other telemetry devices, near infrared sensors, gamma
ray detectors, H.sub.2S detectors, CO.sub.2 detectors, downhole
memory units, downhole controllers, locators, and other downhole
devices therein. In addition, the control line 46 itself may
comprise an intelligent completions device as in the example of a
fiber optic line that provides functionality, such as temperature
measurement, pressure measurement, and the like. In one example,
the fiber optic line provides a distributed temperature
functionality so that the temperature along the length of the fiber
optic line may be determined. The control line 46 for such
equipment would also extend through the seal assembly 42.
[0030] In a multi-zone well, such as that shown in FIG. 1, the
completion 40 has additional isolation assemblies 56 corresponding
to associated zones 6 as desired.
[0031] In one embodiment, a locator device 60 ensures the proper
alignment between the completion 40 and the sand control completion
10. An example of a locator device is shown in FIG. 1. In that
example, the bottom 62 of completion 40 lands on a shoulder 64
connected to a lower end of the sand control completion 10. In that
example, the shoulder 64 is positioned below the sump packer 12.
Numerous other types of locators may be used.
[0032] FIGS. 4 and 5 provide a more detailed illustration of the
seal assembly 42. In many cases, the radial limitations of placing
a completion 40 within the sand control completion 10 are
stringent. To facilitate placement of the control lines 46 in the
radially restricted space, the seal assembly 42 may be eccentric
with the primary production passageway 66 offset from the
centerline of the seal assembly 42. An eccentric arrangement
provides a relatively thicker side through which control line(s) 46
may extend. The control lines 46 extend through control line
passageways provided in the body of the seal assembly 42.
[0033] In another embodiment, shown in FIG. 3, the completion 40 is
used in conjunction with a preexisting completion 70 to provide a
remedial system. As an example, a completion 70, as described in
U.S. patent application Ser. No. 09/732,134, filed Dec. 7, 2000
which is hereby incorporated by reference herein, is provided in a
well 2. In one embodiment, the completion 70 has a sand screen 18
with a gravel pack. A base pipe 72 of the sand screen 18 is
unperforated and defines a flow annulus 74 between the sand screen
18 and the base pipe 72. The annulus communicates with a flow
control valve 44 that controls the flow from the annulus 74 into
the production string 50.
[0034] In the present embodiment, the completion 70 further
includes a pair of inner PBRs 30 isolating the inlet to the
production tubing (i.e., the valve 44 port). For example, an inner
PBR 30 may be placed below the valve 44 and above the sand screen
18. In this way, if the valve 44 fails, it can be locked open and
an inner completion 40 may be run inside completion 70. As in the
previously described embodiment, the seal assemblies 42 of the
completion 40 may mate with the inner PBRs to isolate the incoming
flow which may then be controlled by the valve 44 in the inner
completion 40. This system will work in other situations wherein
there is a specific area of ingress into the production tubing and
an interior completion 40 is desired to control the flow
therethrough, such as in cases of remediation.
[0035] Although the isolation is described herein as using PBRs and
seal assemblies, other types of isolation devices, such as packers
and cup packers, may be used. In one embodiment an inner completion
40 of the present invention may be used in a pre-existing
completion that does not have a PBR. In this embodiment, the inner
completion uses inner packers 80 to isolate between the various
zones. In this way, an intelligent completion may be provided in an
existing well. Referring to FIG. 6, one example of this embodiment
is shown. In FIG. 6, the pre-existing completion comprises an upper
packer 22, a sand screen 18 in each of the zones, and a packer 22
isolating the two zones. The inner completion 40 comprises a valve
44 for each of the zones and inner packers 80 on isolating the
valves 44 from one another. The inner packers 22 seal between the
inner string 82 and the pre-existing completion. The inner packers
22 and valves 44 are positioned in the well so that flow of each of
the screens or zones is isolated from the flow of other screens or
zones (although one valve could be used for multiple zones if
desired). A control line 46 may run from the surface or from a
downhole controller to each of the valves 44 so that the position
of the valve may be controlled. Other intelligent completions
devices may be placed in the inner completion 40 as well. The
control line 46 may extend through bypass lines in the inner
packers 80 which may be eccentric to provide additional area for
running of the control lines 46 therethrough.
[0036] When a device is described herein as providing a seal, some
leakage through the seal may occur. Thus, a seal includes an
arrangement that substantially restricts the flow. The term "seal"
as used herein refers generically to seal assemblies, packers, cup
packers, and other isolation devices.
[0037] Also note that in each of the above-described embodiments,
the sand screen 18 may be replaced with a slotted liner as an
alternative form of sand control. The term "sand control device" is
used to generally describe sand screens, liners, and other types of
conduits used to prevent migration of sand into the production.
[0038] Although only a few exemplary embodiments of this invention
have been described in detail above, those skilled in the art will
readily appreciate that many modifications are possible in the
exemplary embodiments without materially departing from the novel
teachings and advantages of this invention. Accordingly, all such
modifications are intended to be included within the scope of this
invention as defined in the following claims. In the claims,
means-plus-function clauses are intended to cover the structures
described herein as performing the recited function and not only
structural equivalents, but also equivalent structures. Thus,
although a nail and a screw may not be structural equivalents in
that a nail employs a cylindrical surface to secure wooden parts
together, whereas a screw employs a helical surface, in the
environment of fastening wooden parts, a nail and a screw may be
equivalent structures. It is the express intention of the applicant
not to invoke 35 U.S.C. .sctn.112, paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim
expressly uses the words `means for` together with an associated
function.
* * * * *