U.S. patent application number 10/644723 was filed with the patent office on 2005-02-24 for isolation packer inflated by a fluid filtered from a gravel laden slurry.
Invention is credited to Hailey, Travis T. JR..
Application Number | 20050039917 10/644723 |
Document ID | / |
Family ID | 34194161 |
Filed Date | 2005-02-24 |
United States Patent
Application |
20050039917 |
Kind Code |
A1 |
Hailey, Travis T. JR. |
February 24, 2005 |
Isolation packer inflated by a fluid filtered from a gravel laden
slurry
Abstract
Tools and methods for completing a wellbore that comprise an
isolation packer with a particulate filter and inflatable element.
The isolation packer is adapted to direct a gravel laden slurry to
the particulate filter, where the filter removes a substantial
amount of the particulate matter from the gravel laden slurry
thereby producing an inflating fluid that is substantially free of
particulate matter. The inflating fluid then inflates the
inflatable element thereby creating a seal in the wellbore.
Inventors: |
Hailey, Travis T. JR.;
(Sugar Land, TX) |
Correspondence
Address: |
Godwin Gruber
Suite 1700
1201 Elm Street
Dallas
TX
75270
US
|
Family ID: |
34194161 |
Appl. No.: |
10/644723 |
Filed: |
August 20, 2003 |
Current U.S.
Class: |
166/287 ;
166/184; 166/387; 166/51 |
Current CPC
Class: |
E21B 33/127 20130101;
E21B 43/04 20130101 |
Class at
Publication: |
166/287 ;
166/387; 166/051; 166/184 |
International
Class: |
E21B 033/13 |
Claims
What is claimed is:
1. An inflatable well completion tool comprising: an inflatable
element; a particulate filter operatively coupled to the inflatable
element; and wherein the inflatable element is adapted for
inflation by an inflating fluid obtained from filtering a gravel
laden slurry using the particulate filter.
2. The well completion tool of claim 1 wherein the inflatable
element is capable of movement between a deflated state and an
inflated state.
3. The well completion tool of claim 2 wherein the inflatable
element comprises a top end, a bottom end, an interior, and a
passageway allowing communication of the inflating fluid between
the top end of the inflatable element and the interior of the
inflatable element.
4. The well completion tool of claim 3 wherein the passageway
comprises at least one shunt tube.
5. The well completion tool of claim 3 wherein the passageway
comprises at least one alternative channel.
6. The well completion tool of claim 3 wherein the inflatable
element further comprises a passageway allowing communication of
the inflating fluid between the bottom end of the inflatable
element and the interior of the inflatable element.
7. The well completion tool of claim 6 wherein the passageway
comprises a check valve that restricts reverse flow.
8. The well completion tool of claim 1 further comprising: a first
sand screen; a second sand screen; and wherein the inflatable
element isolates the first sand screen from the second sand
screen.
9. The well completion tool of claim 1 further comprising: a sand
screen; and wherein the inflatable element is placed below the sand
screen and isolates the sand screen from the well below the
inflatable element.
10. An isolation packer for use in a wellbore comprising: an
inflatable element; a passageway communicating between an exterior
and an interior of the inflatable element; a particulate filter
located on the passageway; and wherein the inflatable element is
capable of being inflated by an inflating fluid obtained from
filtering, by the particulate filter, a gravel laden slurry
traveling on the passageway.
11. The isolation packer of claim 10 wherein the passageway
comprises at least one shunt tube.
12. The isolation packer of claim 10 wherein the passageway
comprises at least one alternative channel.
13. The isolation packer of claim 10 further comprising: a first
sand screen; a second sand screen; and wherein the inflatable
element isolates the first sand screen from the second sand
screen.
14. The isolation packer of claim 10 further comprising: a
lowermost sand screen; and wherein the inflatable element is placed
below the lowermost sand screen and isolates the lowermost sand
screen from the well below the inflatable element.
15. The isolation packer of claim 10 wherein the passageway
comprises a check valve that restricts reverse flow.
16. The isolation packer of claim 10 further comprising a tubular
body attached to the inflatable element.
17. A wellbore isolation device comprising: a tubular body member
having first and second segments, each segment having an exterior
and a longitudinal bore extending therethrough; a bladder
surrounding the second segment of the tubular body, the bladder
having a wall, an interior, an upper end, and a lower end; a
passageway located adjacent the exterior of the first segment and
extending through the wall of the bladder element; a particulate
filter located on the passageway and operatively coupled to the
interior of the bladder; and wherein the passageway allows a gravel
laden slurry to be filtered by the particulate filter thereby
producing an inflating fluid which enters and expands the
bladder.
18. The device of claim 17, wherein the passageway comprises a
check valve that restricts reverse flow.
19. The device of claim 17, wherein the bladder is expandable in a
radial direction.
20. The device of claim 19, wherein the bladder is attached to the
tubular body member.
21. The device of claim 20, wherein the bladder has an upper end
and a lower end, and both the upper end and the lower end are
connected to the tubular body member.
22. The device of claim 21 wherein the second tubular body segment
comprises an upper packer head and a lower packer head, and the
bladder upper end is connected to the upper packer head and the
bladder lower end is connected to the lower packer head.
23. The device of claim 22 wherein the passageway extends through
the upper packer head and communicates between the exterior of the
first segment of the tubular body member and the interior of the
bladder.
24. The device of claim 22 wherein the passageway extends through
the upper and lower packer heads and communicates between the
exterior of the first and second segments of the tubular body
member and the interior of the bladder.
25. The device of claim 17 wherein the passageway enables
communication between the exterior of the first segment of the
tubular body member and the interior of the bladder.
26. The device of claim 17 further comprising a third segment of
the tubular body member wherein the passageway enables
communication between the exterior of the first and third segments
with the interior of the bladder.
27. The device of claim 17 wherein the passageway comprises a shunt
tube.
28. The device of claim 17 wherein the passage way comprises an
alternative channel.
29. A wellbore isolation tool comprising: a tubular body having a
longitudinal bore therethrough and an exterior; an expandable
bladder attached to the tubular body; a passageway providing
communication between the expandable bladder and the exterior of
the tubular body; a particulate filter communicably coupled to the
expandable bladder and located on the passageway; and wherein the
passageway allows a gravel laden slurry to be filtered by the
particulate filter thereby producing an inflating fluid which
enters and expands the expandable bladder.
30. The wellbore isolation tool of claim 29 wherein the passageway
comprises a check valve that restricts reverse flow.
31. The wellbore isolation tool of claim 31 wherein the bladder has
an upper end and a lower end, and both the upper end and the lower
end are connected to the tubular body.
32. The wellbore isolation tool of claim 29 wherein the passageway
comprises a shunt tube.
33. The wellbore isolation tool of claim 29 wherein the passage way
comprises an alternative channel.
34. An isolation packer system for use in a wellbore comprising: a
tubular body member having first, second and third segments, the
first and third segments being on opposite ends of the second
segment, each segment having an exterior and a longitudinal bore
extending therethrough; a bladder surrounding the second segment of
the tubular body, the bladder having a wall and an interior; a
passageway located adjacent the first and third segments and
extending through the wall of the bladder; at least one particulate
filter located on the passageway and in communication with the
bladder; and wherein the passageway allows a gravel laden slurry to
be filtered by the particulate filter thereby producing an
inflating fluid which enters and expands the bladder.
35. The system of claim 34 wherein the passageway enables
communication between the exterior of the first and third segments
with the interior of the bladder.
36. The system of claim 34 wherein during a gravel pack completion
of a wellbore the passageway allows the gravel laden slurry to
communicate between the exterior of the first and third segments
and the at least one particulate filter.
37. The system of claim 34 wherein the passageway comprises a check
valve that restricts reverse flow.
38. The system of claim 34 wherein the at least one particulate
filter comprises a check valve that restricts reverse flow.
39. The system of claim 34 wherein the bladder is capable of radial
expansion upon being filled with the inflating fluid.
40. The system of claim 39 whereupon radial expansion the bladder
forms a seal between the tubular body and the wellbore wall.
41. The system of claim 34 wherein the passageway comprises a shunt
tube.
42. The system of claim 34 wherein the passage way comprises an
alternative channel.
43. The system of claim 34 further comprising a cup packer affixed
along some portion of the wellbore wall for creating a pressure
seal.
44. A method of sealing an annulus in a well, comprising the steps
of: filtering a gravel laden slurry to produce an inflating fluid;
and expanding an inflatable element with the inflating fluid.
45. The method of claim 44 further comprising the step of
communicating, over a passageway, the inflating fluid between an
exterior and an interior of the inflatable element.
46. The method of claim 45 further comprising the step of
restricting reverse flow of the inflating fluid on the passageway
with a check valve.
47. The method of claim 44 further comprising the step of obtaining
the gravel laden slurry from a gravel packing of the well.
48. The method of claim 44 further comprising the step of: sealing
an annulus of the well; and isolating a first zone from a second
zone.
49. A method of completing a well comprising the steps of:
providing a sand screen completion having at least one inflatable
element therein; gravel packing at least a portion of the well with
a gravel slurry; filtering the gravel slurry with a particulate
filter to produce an inflating fluid; and inflating the inflatable
element with the inflating fluid.
50. The method of claim 49 further comprising the step of:
communicating between an exterior and interior of the inflatable
element with a passageway.
50. The method of claim 49 further comprising the step of
restricting reverse flow on the passageway with a check valve.
51. The method of claim 49 further comprising the step of passing a
portion of the gravel slurry through the passageway.
52. The method of claim 51 further comprising the steps of: sealing
an annulus of the well with the inflatable element; and isolating a
first zone from a second zone.
Description
TECHNICAL FIELD
[0001] This invention generally relates to inflatable packers used
to complete subterranean wells and in particular to hydraulically
actuated inflatable packers. More specifically, this invention
relates to hydraulically actuated inflatable packers that are
inflated by a fluid filtered from a gravel laden slurry or other
fluid with suspended solids.
BACKGROUND OF THE INVENTION
[0002] Oil and natural gas may be obtained from subterranean
geologic formations, referred to as reservoir, by drilling wells
that penetrate hydrocarbon-bearing formations. In order to obtain
hydrocarbons from a wellbore, the well usually must be
completed.
[0003] Well completion involves the design, selection, and
installation of equipment and materials in or around a wellbore for
conveying, pumping, or controlling the production or injection of
fluids from and/or to the wellbore. After a well has been
completed, production of oil and gas may begin. Sand or silt
flowing into the wellbore from unconsolidated formations may lead
to an accumulation of fill within the wellbore which may cause a
reduction of production rates and damage to surface and subsurface
production equipment. The fill, often referred to as migrating
sand, has the possibility of packing off around subsurface
production equipment, or may enter the production tubing and
therefore enter production equipment. Sand is highly abrasive, and
if it enters production streams, it may cause the erosion of
tubing, flowlines, valves and other processing components and
equipment. Erosion and abrasion caused by sand production often
increases operational and maintenance expenses, and in severe cases
may lead to a total loss of the well. Gravel packing is a means of
controlling sand production. Gravel packing is the placement of
relatively large sand (i.e., "gravel") around the exterior of a
sand screen or liner, which includes slotted sand screens,
perforated sand screens, and various other liner types and screens.
The gravel acts as a filter to remove formation fines and sand from
oilfield fluids.
[0004] A gravel pack completion known in the art comprises a sand
screen that is placed in the wellbore and positioned within an
unconsolidated formation. The sand screen may be connected to a
tool that includes a production packer and a cross-over. The tool
is connected to a work string or a production tubing string. Gravel
is then pumped in a slurry down the tubing and through the
cross-over, thereby flowing into the annulus between the sand
screen and the wellbore. The slurry comprises a liquid supporting
suspended solids. The solids are often referred to as "gravel". The
liquid leaks off into the formation and/or through the sand screen,
which is sized to prevent the solids in the slurry from flowing
through. Thus the solids are deposited in the annulus around the
sand screen where it forms a gravel pack. The sand screen prevents
the gravel pack from entering into the production tubing. The
gravel must be sized for proper containment of the formation sand,
and the sand screen must be designed in a manner to prevent the
flow of the gravel through the sand screen.
[0005] Often during well completions there is a need to seal off
sections of the wellbore. One reason to seal off a section of a
wellbore is the need to isolate those areas in which an adequate
gravel pack can not be obtained, such as below the bottom of the
gravel pack screens where adequate circulation is difficult to
achieve. Another reason to seal off a section of a wellbore is that
in some formations, such as across a major or minor shale section,
a gravel pack completion is not desirable. Still another reason to
seal off a section of a well bore is because when one or more
sections are to be completed and another section is not going to be
completed, the non-completed section often needs to be isolated
from the sections that will be completed. This is due to the fact
that when non-completed sections are not isolated, the gravel,
which is tightly packed around the gravel pack screens after a
gravel pack, may be able to migrate to these non-completed
sections, thereby limiting the effectiveness of the gravel pack
completion. Another reason to isolate a section of the wellbore is
to prevent or limit acceleration of the gravel migration effect due
to the flow of produced fluids. Sand screens exposed to gravel
migration due to the flow of produced fluids may experience direct
production of formation sand which could result in equipment
damage, formation collapse and even the loss of the well.
[0006] Well known in the art are inflatable packers, usually
comprising an annular elastomeric bladder, which have been used to
seal off sections of wellbores for the reasons discussed above.
When the bladder is filled by a by a pressurized fluid, it inflates
the packer causing the exterior of the elastomeric body to seal
against the wellbore. This produces a wellbore seal that prohibits
fluid flow past the packer.
[0007] A problem with inflatable packers known in the art is the
difficulty of sending fluid to the bladder to inflate the bladder.
The time consumed in using known inflatable packers includes the
time needed for an extra step either prior to the gravel pack step
or after the gravel pack step to send a specialized tool down the
wellbore to inflate the packer.
[0008] Thus, there is a need for an improved inflatable packer
which reduces the known problems in sending fluid to the bladder to
inflate the bladder, and eliminates the need for an extra step
either prior to or after a gravel pack to inflate the bladder.
SUMMARY OF THE INVENTION
[0009] The present invention describes tools and methods of
completing a wellbore that comprise an isolation packer with a
particulate filter and inflatable element. The isolation packer is
adapted to direct a gravel laden slurry to the particulate filter,
where the filter removes a substantial amount of the particulate
matter from the gravel laden slurry thereby producing an inflating
fluid that is substantially free of particulate matter. The
inflating fluid then inflates the inflatable element thus creating
a seal in the wellbore.
[0010] This invention offers a number of benefits over conventional
wellbore completion tools. Usually a pre-gravel pack trip would be
undertaken to isolate a sump area, for instance, with a cement plug
or an open hole packer. This pre-gravel pack trip comprise
additional steps that are costly, time consuming and are often
difficult to perform and unreliable in their outcome. The present
invention provides a means of achieving the desired results in the
same trip into the well as the gravel pack operation. The ability
to inflate the inflatable isolation packer during a gravel pack
completion can save time and expense by eliminating an additional
trip into the well.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above advantages as well as specific embodiments will be
understood from consideration of the following detailed description
taken in conjunction with the appended drawings in which:
[0012] FIG. 1 is a cross section of a wellbore showing a prior art
gravel pack completion apparatus.
[0013] FIG. 2 is a cross section of a wellbore showing a gravel
pack completion apparatus that includes an embodiment of the
present invention.
[0014] FIGS. 3A and 3B are cross sections of a wellbore showing a
gravel pack completion with both a typical isolation packer (FIG.
3A) and with a cup packer (FIG. 3B) with the particulate filter
located near an uphole end of the conduit.
[0015] FIG. 4 is a cross section of a wellbore showing an
embodiment of the present invention with the inflatable element
shown in an inflated state.
[0016] FIG. 5 is a partial cut away view of another embodiment of
the present invention comprising an alternative channel.
[0017] FIG. 6 is a partial cut away view of the present invention
comprising an alternative channel with the particulate filter
located near an uphole end of the alternative channel.
[0018] FIG. 7 is a partial cut away view of the alternative channel
embodiment of the present invention showing the inflatable element
in an inflated state.
[0019] FIG. 8 is a cross section of a wellbore showing another
embodiment of the present invention in an openhole completion.
[0020] FIG. 9 is a cross section of a wellbore showing the
embodiment of the present invention in an openhole completion with
the inflatable element in an inflated state.
[0021] References in the detailed description correspond to like
references in the figures unless otherwise indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to the attached drawings, FIG. 1 is a depiction of
the prior art and illustrates a wellbore 10 that has penetrated a
subterranean zone 12 that includes a productive formation 14. The
wellbore 10 has a casing 16 that has been cemented in place. The
casing 16 has a plurality of perforations 18 which allow fluid
communication between the wellbore 10 and the productive formation
14. A well tool 20 is positioned within the casing 16 in a position
adjacent to the productive formation 14, which is to be gravel
packed.
[0023] The present invention can be utilized in both cased wells
and open hole completions, as well as vertical wells and
non-vertical wells. For ease of illustration of the relative
positions of the producing zones in FIGS. 1-4, a cased well having
perforations will be used. More detailed illustrations of the
invention being utilized in an open hole completion are shown in
FIGS. 8-9.
[0024] Still referring to FIG. 1, the well tool 20 comprises a
tubular member 22 attached to a production packer 24, a closing
sleeve 26, and one or more sand screen elements 28. Blank sections
of pipe may be used to properly space the relative positions of
each of the components. An annulus area 34 is created between each
of the components and the wellbore casing 16. The combination of
the well tool 20 and the tubular string extending from the well
tool to the surface can be referred to as the production
string.
[0025] Still referring to FIG. 1, in a gravel pack operation the
packer 24 is set to ensure a seal between the tubular member 22 and
the casing 16. Gravel laden slurry is pumped down the tubular
member 22, exits the tubular member through ports in the closing
sleeve 26 and enters the annulus area 34 below the production
packer 24. In one typical embodiment the particulate matter
(gravel) in the slurry has an average particle size between about
40/60 mesh-12/20 mesh, although other sizes may be used. Slurry
dehydration occurs when the carrier fluid leaves the slurry. The
carrier fluid can leave the slurry by way of the perforations 18
and enter the formation 14. The carrier fluid can also leave the
slurry by way of the sand screen elements 28 and enter the tubular
member 22. The carrier fluid flows up through the tubular member 22
until the closing sleeve 26 places it in the annulus area 36 above
the production packer 24 where it can leave the wellbore 10 at the
surface. Upon slurry dehydration the gravel grains should pack
tightly together. The final gravel filled annulus area is referred
to as a gravel pack.
[0026] An area that is prone to developing a void during a gravel
pack operation is the area 42 below the lowest sand screen element
28, sometimes referred to as the "sump". A gravel pack void in the
sump 42 is particularly problematic in vertical wells in that it
can allow the gravel from above to settle and fall into the voided
sump.
[0027] Production of fluids from the productive formation 14 can
agitate or "fluff" the gravel pack and initiate the gravel to
migrate and settle within the sump 42. This can lead to the
creation of voids in the annulus areas 38 adjacent to the sand
screen elements 28 and undermine the effectiveness of the entire
well completion.
[0028] As used herein, the term "sand screen" refers to wire
wrapped screens, mechanical type screens and other filtering
mechanisms typically employed with sand screens. Sand screens need
to be have openings small enough to restrict gravel flow, often
having gaps in the 60-12 mesh range, but other sizes may be used.
Sand screens of various types are produced by Halliburton, among
others, and are commonly known to those skilled in the art.
[0029] FIG. 2 illustrates one particular embodiment of the present
invention where an upper set of perforations 60 and a lower set of
perforations 62 will be completed utilizing a gravel pack
completion. The lower set of perforations 62 will be isolated from
the upper set of perforations 60. An inflatable isolation packer 50
is run into the wellbore 10 below the lowest sand screen element
28. A conduit 52 extends from the gravel inflated isolation packer
50 and provides communication with the annulus area 38 that will be
gravel packed. The conduit 52 may be generally referred to as a
passageway, and more specifically referred to as a shunt tube. A
second conduit 53 may be utilized below the isolation packer
50.
[0030] Between the conduit 52 and the gravel inflated isolation
packer 50 is a particulate filter 54. Likewise, a particulate
filter 59 is placed between conduit 53 and the isolation packer 50.
In this way, either or both of the conduits 52, 53 allow gravel
laden slurry to travel from the annulus area 38 to the particulate
filters 54, 59 where the gravel laden slurry is filtered, thereby
providing an inflating fluid. The inflating fluid is then
communicated to an inflatable element 56 that provides the sealing
mechanism between the tubular member 22 and the casing 16. The
inflatable element 56 may be an expandable bladder. The particulate
filter 54 could be any device known in the art that separates the
particulate matter in the gravel laden slurry from the carrying
fluid. Some examples of particulate filters include, but are not
limited to: wire-wrapped screens and wire meshes.
[0031] A conduit, such as conduit 52 and/or conduit 53, is just one
way of enabling the communication of the gravel laden slurry to
enter the inflatable isolation packer 50. Other embodiments can be
used, such as connecting the inflatable isolation packer 50 to a
flow channel which is integral to the screen, or a shunt tube. All
of these embodiments would include a particulate filter to prevent
particulates such as gravel from entering the inflatable element
56. In addition, all of these embodiments may include a check valve
device to prevent any reverse flow out of the inflatable isolation
packer 50.
[0032] The inflation of the inflatable element 56 will typically be
done with a fluid that is filtered from a gravel laden slurry. This
fluid will be an inflating fluid that is substantially free of
particulates such as gravel. The inflation of the inflatable
element 56 can be performed in conjunction with a gravel pack
completion operation of the well.
[0033] The inflatable element 56 may be constructed utilizing an
inner elastomeric element that retains the pressurized fluid that
is used to inflate the packer. The inflatable element may comprise
more than one layer of material, such as utilizing an expandable
mesh as an outer layer for durability. Often a plurality of metal
reinforcing members can be located in the annulus between the
elastomeric element and the outer expandable mesh, these provide
additional strength to the packer and can improve reliability. The
typical construction can be in the manner of conventional packers,
these methods and materials being well known to those skilled in
the art.
[0034] FIGS. 3A and 3B illustrate alternate embodiments of the
invention where the particulate filter 54 is no longer located
adjacent to the inflatable element 56, but rather is now located
near the uphole end of the conduit 52. The particulate filter 54
may be located at various locations on the well tool 20 so long as
the particulate filter is able to filter the particulates from the
gravel slurry so that an inflating fluid is produced that is
substantially free of particulate matter and can be used to inflate
the inflatable element 56. Multiple conduits may be used, one or
more with ports as depicted in FIG. 2 in addition to one or more
without ports as shown in FIG. 3A, as long as at least one conduit
supplies inflating fluid through a particulate filter that can
inflate the inflatable element.
[0035] FIG. 3B shows the use of a cup packer 55 placed below the
entrance to conduit 52 but above the first opening of sand screen
elements 28. As is known in the arts, the use of a cup packer, such
as cup packer 55, creates a pressure seal between well tool 34 and
the well bore wall 16 except for the passage way through the
conduit, such as conduit 52, or the conduits allowing a forced flow
through the conduit or conduits.
[0036] FIG. 4 illustrates the embodiment of the invention as
described in FIG. 2 after a gravel pack operation has been
performed. The inflatable element 56 of the inflatable isolation
packer 50 is expanded and provides a seal between the tubular
member 22 and the casing 16. The upper and lower set of
perforations 60 and 62 have been properly gravel packed and
protected from the producing formation 14. The inflatable isolation
packer 50 acts to isolate the gravel pack completed lower set of
perforations 62 from the gravel pack completed upper set of
perforations 60. Also shown in FIG. 4 is the use of a second
isolation packer 150 which can be used and operated in a manner
similar to isolation packer 50.
[0037] For ease of installation and to ensure proper placement
relative to the components of the well tool 20, the conduit 52 that
extends from the inflatable isolation packer 50 will typically be
attached to the exterior of the well tool 20 in some manner, such
as by welding. It is also possible for the conduit 52 to be
replaced by a fluid pathway forming an alternative channel within a
sand screen element, as described with respect to FIGS. 5-7. Also,
the particulate filters may be located adjacent or near the
inflatable element 56.
[0038] Referring now to FIG. 5, there is depicted a partial cut
away view of an apparatus 64 that is an alternative channel
embodiment of the invention. Apparatus 64 has an outer tubular 66.
A portion of the side wall of outer tubular 66 is an axially
extending production section 68 that includes a plurality of
openings 70. Another portion of the side wall of outer tubular 66
is an axially extending nonproduction section 72 that is
distinguished from the production section 68 by the lack of
openings 70. It should be noted by those skilled in the art that
even though FIG. 5 has depicted openings 70 as being circular,
other shaped openings may alternatively be used without departing
from the principles of the present invention. In addition, the
exact number, size and shape of openings 70 are not critical to the
present invention, so long as sufficient area is provided for fluid
production therethrough and the integrity of outer tubular 66 is
maintained.
[0039] Still referring to FIG. 5, disposed within outer tubular 66
and on opposite sides of each other is one or more channels 74,
only one channel 74 being visible. Channels 74 provide
circumferential fluid isolation between production section 68 and
nonproduction section 72 of outer tubular 66. Channels 74 may be
generally referred to as passageways.
[0040] Still referring to FIG. 5, disposed within channels 74 is a
sand control screen assembly 78. The sand control screen assembly
78 may include a base pipe 80 that has a plurality of openings 82
which allow the flow of production fluids into the production
tubing. The exact number, size and shape of openings 82 are not
critical to the present invention, so long as sufficient area is
provided for fluid production and the integrity of base pipe 80 is
maintained. Positioned around base pipe 80 is a fluid-porous,
particulate restricting, sintered metal material such as plurality
of layers of a wire mesh that are sintered together to form a
porous sintered wire mesh screen 84. Sand screen 84 is designed to
allow fluid flow therethrough but prevent the flow of particulate
materials of a predetermined size from passing therethrough. It
should be understood by those skilled in the art that other
configurations of the sand screen assembly 78 may be used in
conjunction with the alternative channel embodiment 64 of the
invention, for instance, the sand screen assembly may also have a
screen housing located between the channels 74 and the sand screen
84, or different screening materials may be used in stead of the
sand screen 84.
[0041] Still referring to FIG. 5, in this embodiment, the channels
74 are analogous to the conduit 52 from FIGS. 2-4, in that a gravel
laden slurry may travel down the channels 74 to a particulate
filter 54, which filters out particulates such as gravel. Once the
gravel laden slurry is filtered, a substantially particulate-free
fluid thereby communicates with an inflatable isolation packer 50
and expands inflatable element 56. FIG. 6 shows another embodiment
of the alternative channel apparatus 64 wherein the particle filter
54 is located nearer the uphole end of the alternative channel 74,
instead of being adjacent to the inflatable isolation packer 50.
FIG. 7 shows the alternative channel apparatus 64 with the
inflatable element 56 expanded to form a seal with the casing 16 to
isolate the annular area 38 from the space 86 below the packer
[0042] FIG. 8 illustrates an embodiment of the gravel inflated
isolation packer 50 utilized in an openhole environment. This
embodiment comprises a tubular member 22, a conduit 52, two
particulate filters 54, an expandable element 56, an upper packer
head 88, and a lower packer head 90. This illustration shows an
embodiment of the present invention wherein the conduit 52 extends
out both the upper packer head 88 and the lower packer head 90. The
conduit 52 provides two pathways, one for communication to the
expandable element 56, and the second for communication to annular
areas 92 and 94.
[0043] FIG. 9 shows the inflatable isolation packer 50 as
illustrated in FIG. 8 and described above with the inflatable
element 56 in an inflated state and filled with inflating fluid.
The inflated inflatable element 56 forms a seal between in the
wellbore thereby isolating annular area 92 from annular area
94.
[0044] The inflatable isolation packer 50 acts to isolate a first
zone from a second zone within the well. In FIG. 4, an annulus area
that is gravel packed is being isolated from a lower annulus area
of the well that is also gravel packed. Other embodiments can be
used to separate a gravel packed annulus area from a non-gravel
packed annulus area, a gravel packed annulus area from a sump area
or other combinations such as these. In other embodiments, a
lateral wellbore may be isolated from a main wellbore, multiple
lateral wellbores may be isolated from each other, and length of a
lateral wellbore being gravel packed may be effectively shortened.
The ability to inflate the inflatable isolation packer 50 during a
gravel pack completion can save time and expense by eliminating an
additional trip into the well.
[0045] FIGS. 1-3 shows the invention used between two gravel packed
zones, whereby the invention is isolating the two gravel packed
zones from each other. This embodiment can be used to selectively
work on or produce from the separate zones.
[0046] In another embodiment the invention may be placed below the
lowest perforation or at the bottom of the well. This embodiment
may be used to isolate the lower areas from the completed zones
without permanently reducing the total depth of the well. Thus, the
well could be functionally plugged back to where the inflatable
isolation packer was located and leaving open the option of
removing the inflatable isolation packer for the completion of
deeper zones in the future.
[0047] The discussion and illustrations within this application may
refer to a vertical wellbore that has casing cemented in place, or
is an openhole bore, and comprises casing perforations to enable
communication between the wellbore and the productive formation. It
should be understood that the present invention can also be
utilized with wellbores that have an orientation that is deviated
from vertical.
[0048] The particular embodiments disclosed herein are illustrative
only, as the invention may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. Furthermore, no limitations
are intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular embodiments disclosed above may be
altered or modified and all such variations are considered within
the scope and spirit of the invention. Accordingly, the protection
sought herein is as set forth in the claims below.
* * * * *