SLIDING SLEEVE VALVE ASSEMBLY WITH SAND SCREEN
A system and method for completing a well with multiple zones of production is provided, including a casing having a plurality of valves integrated therein for isolating each well zone, establishing communication between each underlying formation and the interior of the casing, delivering a treatment fluid to each of the multiple well zones, and filtering produced fluids from each underlying formation.
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This application is a continuation-in-part of U.S. patent application Ser. No. 11/834,869, filed Aug. 7, 2007, and entitled “System For Completing Multiple Well Intervals,” which is a divisional application of U.S. patent application Ser. No. 10/905,073, filed Dec. 14, 2004, and entitled “System For Completing Multiple Well Intervals.” This application further claims priority to U.S. Provisional Application No. 60/938,920, filed May 18, 2007, entitled “Sliding Sleeve Valve Assembly with Sand Screen;” and U.S. Provisional Application No. 60/987,302, filed Nov. 12, 2007, entitled “Sliding Sleeve Valve Assembly with Sand Screen.”
TECHNICAL FIELDThe present invention relates generally to recovery of hydrocarbons in subterranean formations, and more particularly to a system and method for delivering treatment fluids to wells having multiple production zones or a single production zone with a relatively large reservoir height.
BACKGROUNDIn typical wellbore operations, various treatment fluids may be pumped into the well and eventually into the formation to restore or enhance the productivity of the well. For example, a non-reactive “fracturing fluid” or a “frac fluid” may be pumped into the wellbore to initiate and propagate fractures in the formation thus providing flow channels to facilitate movement of the hydrocarbons to the wellbore so that the hydrocarbons may be pumped from the well. In such fracturing operations, the fracturing fluid is hydraulically injected into a wellbore penetrating the subterranean formation and is forced against the formation strata by pressure. The formation strata is forced to crack and fracture, and a proppant is placed in the fracture by movement of a viscous-fluid containing proppant into the crack in the rock. The resulting fracture, with proppant in place, provides improved flow of the recoverable fluid (i.e., oil, gas or water) into the wellbore. In another example, a reactive stimulation fluid or “acid” may be injected into the formation. Acidizing treatment of the formation results in dissolving materials in the pore spaces of the formation to enhance production flow.
Currently, in wells with multiple production zones, it may be necessary to treat various formations in a multi-staged operation requiring many trips downhole. Each trip generally consists of isolating a single production zone, perforating the isolated zone, and then delivering the treatment fluid to the isolated zone. Since several trips downhole are required to isolate and treat each zone, the complete operation may be very time consuming and expensive.
Accordingly, there exists a need for systems and methods to deliver treatment fluids to multiple zones of a well in a single trip downhole.
SUMMARYThe present invention relates to a system and method for delivering a treatment fluid to a well having multiple production zones or a single production zone with a relatively large reservoir height. According to some embodiments of the present invention, a well completion system having one or more zonal communication valves is installed and/or deployed in a wellbore to provide zonal isolation and establish hydraulic communication with each particular well zone for facilitating delivery of a treatment fluid or squeezing remedial cement. Each communication valve may be set to an open position, a closed position, and a filtering position.
Other or alternative embodiments of the present invention will be apparent from the following description, from the drawings, and from the claims.
The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
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 INVENTIONIn 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.
In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via another element”; and the term “set” is used to mean “one element” or “more than one element”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. Moreover, the term “sealing mechanism” includes: packers, bridge plugs, downhole valves, sliding sleeves, baffle-plug combinations, polished bore receptacle (PBR) seals, and all other methods and devices for temporarily blocking the flow of fluids through the wellbore. Furthermore, the term “treatment fluid” includes any fluid delivered to a formation to stimulate production including, but not limited to, fracing fluid, acid, gel, foam or other stimulating fluid.
Generally, this invention relates to a system and method for completing multi-zone wells (or, alternatively, wells with relatively large reservoir heights) by delivering a treatment fluid to achieve productivity, or for delivering remedial cement to target areas as necessary. Typically, such wells are completed in stages that result in very long completion times (e.g., on the order of four to six weeks). The present invention may reduce such completion time (e.g., to a few days) by facilitating multiple operations, previously done one trip at a time, in a single trip.
In general, embodiments of the present invention include a system of one or more zonal isolation valves movable (e.g., by shifting, rotating, indexing, or other means) between three positions: (1) an open position whereby a treatment fluid may be pumped/injected into the well, (2) a closed position whereby communication is interrupted between the well and the interior of the valve, and (3) a filtering position whereby a fluid (e.g., a produced hydrocarbon or other production or return fluid) is free to flow from the well into the interior of the valve via a filtering medium (e.g., sand screen).
Regarding use of the well completion system of the present invention, some embodiments may be deployed in a wellbore (e.g., an open or uncased hole) as a temporary completion. In such embodiments, sealing mechanisms may be employed between each valve and within the annulus defined by the tubular string and the wellbore to isolate the formation zones being treated with a treatment fluid. However, in other embodiments the valves and casing of the completion system may be cemented in place as a permanent completion. In such embodiments, the cement serves to isolate each formation zone.
The zonal isolation valve 25 includes an outer housing 30 having an axial bore therethrough and which is connected to or integrally formed with a casing (or liner, or any tubular string both cemented or uncemented). The housing 30 has a set of housing ports 32 formed therein for establishing communication between the wellbore and the axial bore of the housing. In some embodiments, the housing may protrude radially outward to minimize the gap between the valve 12 and wellbore 10 (as shown in
Actuation of the zonal communication valve (sliding sleeve and sand screen assemblies) may be achieved by any number of mechanisms including, but not limited to, darts (see U.S. Pub. No. 2006/0124310, which disclosure of dart actuation is incorporated herein by reference), tool strings, control lines, (see U.S. Pub. No. 2006/0124312, which disclosure of control line actuation is incorporated herein by reference), electrical lines selectively powering solenoids for valve shifting, and drop balls (see U.S. Pub. Nos. 2006/0124312 and 2007/0044958, each of which discloses use of drop ball actuation, are incorporated herein by reference). Moreover, embodiments of the present invention may include wireless actuation of the zonal communication valve as by pressure pulse, electromagnetic radiation waves, seismic waves, acoustic signals, and other wireless signaling.
With reference to
In operation, once run-in on casing, installed and cemented into place, a target valve 110 is actuated to shift the sleeve 124 from the closed to the open position. In the embodiment illustrated in
With respect to
The screen protector may be removed to facilitate production by various methods and employing various tools. In one embodiment, as shown in
In another embodiment, as shown in
In still another embodiment, as shown in
Where the sacrificial member 128C is formed of a dissolvable material, in one embodiment, the dissolvable material may be selected to dissolve at a desired rate when exposed to well fluid within wellbore. Accordingly, the dissolving of the temporary covering 128C is controlled by submerging dissolvable material in fluids found within wellbore during movement of the valve 110 to a desired location within the wellbore. Alternatively, fluid agents also can be added to the wellbore to control the dissolving of material. The dissolvable material may be formed from a variety of materials depending on the specific application and environment in which it is used. For example, the materials selected may vary depending on the potential heat and pressures in a given wellbore environment. The materials selected also may depend on the types of well fluids encountered in a given wellbore environment. Examples of dissolvable material comprise highly reactive metals such as calcium, magnesium or alloys thereof, or materials that dissolve in acidic or basic fluids, e.g. aluminum, polymers or specially formulated plastics. Examples of suitable materials used to form a coating comprise aluminum or other metals that can be removed with acid or specifically formulated chemicals. Other examples of materials comprise low-temperature plastics or elastomers that fail at higher pressures or temperatures. Additional examples of suitable materials comprise metallic coatings that differ greatly in thermal expansion coefficient relative to their carrier material, such that the coating material fractures and breaks away at elevated temperatures.
Still with respect to
Now, with respect to moving the filtering assembly into place, the filter assembly may be mechanically shifted across the ports by various methods and employing various tools, including: drop balls, pumped darts, or by mating profiles in the service tool (or other tool string). Other methods of moving the filter assembly include non-mechanical (e.g., hydraulic) means. For example, as shown in
With respect to
In some embodiments of the present invention, the zonal isolation system may include a cable (e.g., running down the outer surface of the casing) for monitoring and surveillance of wellbore parameters, such as pressure, temperature, pH, strain, and so forth. This is possible with embodiments of the present valve-actuated zonal isolation system as perforation operations are not required; and such perforation operations would likely damage any installed cable.
The invention also includes various embodiments of operational methods for treating multiple zones of a well via a zonal isolation system. One example is shown in
Another example is shown in
Yet another example is shown in
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover such modifications and variations as fall within the true spirit and scope of the invention.
Claims
1. A valve apparatus for use in a wellbore intersecting a reservoir, comprising:
- a housing being fixed to the wellbore proximate the reservoir by cement, the housing defining an inner bore and having a port for establishing a flow path between the reservoir and the inner bore of the housing;
- a sliding sleeve arranged within the inner bore of the housing, and being adapted to shift between a closed position whereby the sliding sleeve interrupts the flow path between the reservoir and the inner bore of the housing and an open position whereby the flow path between the reservoir and the inner bore of the housing is substantially uninterrupted; and
- a filtering assembly arranged within the inner bore of the housing axially adjacent to the sliding sleeve, the filtering assembly comprising: a perforated base pipe and a screen arranged between the housing and the perforated base pipe, the filtering assembly being adapted to shift between a filtering position wherein the screen is aligned with the port in the housing and a non-filtering position wherein the screen is not aligned with the port in the housing.
2. The valve apparatus of claim 1, further comprising a protector adapted to engage the base pipe to isolate the screen from the inner bore of the housing.
3. The valve apparatus of claim 2, wherein the protector comprises:
- a removable mechanical sleeve formed around an inner surface of the base pipe having a profile for engagement with an actuator,
- wherein the actuator is one selected from a group consisting of: a drop ball, a dart, and a service tool.
4. The valve apparatus of claim 2, wherein the protector comprises:
- a set of removable plugs inserted into the perforated base pipe and protruding radially inward toward the inner bore of the housing for engagement with an actuator,
- wherein the actuator is one selected from a group consisting of: a drop ball, a dart, and a service tool.
5. The valve apparatus of claim 2, wherein the protector comprises:
- a sacrificial member formed around an inner surface of the base pipe, wherein the sacrificial member is formed from a dissolvable material.
6. The valve apparatus of claim 2, further comprising a sealing mechanism connected to the housing and biased radially inward from the inner bore, the sealing mechanism being adapted to engage a work string extending from a surface location through the inner bore of the housing for delivering cement into the wellbore at a location below the housing.
7. The valve of claim 2, wherein the filtering assembly further comprises a metering surface connected to the base pipe, the metering surface defining a radially-outward protruding profile counter to an inner surface of the housing, the radially-outward protruding profile adapted to meter the shifting of the filtering assembly.
8. A method for use in a wellbore having a plurality of well zones, comprising:
- running a casing having a plurality of valves formed therein from a surface down into the wellbore such that each valve is proximate a well zone;
- cementing the casing to the wellbore;
- selecting a target valve proximate a target well zone;
- opening the target valve to establish communication between the surface and the target well zone;
- treating the target well zone by pumping a treatment fluid from the surface to the target well zone via the target valve; and
- manipulating at least one valve into a filtering state;
- filtering a production fluid flowing from at least one well zone into the casing; and
- producing the production fluid to the surface.
9. The method of claim 8, wherein opening the target valve comprises:
- pumping a dart from the surface into the casing to move a sleeve in the target valve.
10. The method of claim 8, wherein opening the target valve comprises:
- dropping a ball from the surface into the casing to move a sleeve in the target valve.
11. The method of claim 8, wherein opening the target valve comprises:
- running a service tool into the well to the target valve of the target well zone; and
- engaging a sleeve in the target valve with the service tool and shifting the sleeve.
12. The method of claim 8, wherein opening the target valve comprises:
- pressurizing a control line running from a location above the target valve to shift a sleeve in the target valve.
13. The method of claim 8, wherein manipulating at least one valve into a filtering state comprises:
- shifting a sand screen assembly over a port within the at least one valve, the screen assembly comprising: a perforated base pipe and a screen.
14. The method of claim 13, further comprising:
- protecting the screen with a removable sleeve arranged around the perforated base pipe; and
- removing the sleeve from the perforated base pipe before producing the production fluid.
15. The method of claim 13, further comprising:
- protecting the sand screen with a sacrificial member arranged around the perforated base pipe; and
- dissolving the sacrificial member before producing the production fluid.
16. The method of claim 8, further comprising:
- monitoring a well parameter proximate a well zone with a cable running from the surface to the well zone external the casing.
17. A system for use in a wellbore having a plurality of well zones, comprising:
- a casing fixed to the wellbore by cement;
- a plurality of valves connected to the casings, each valve comprising: (i) a flow port for establishing communication between the casing and one of the well zones, (ii) a sliding sleeve disposed therein for regulating communication via the flow port, and (iii) a filtering assembly disposed therein and axially adjacent to the sliding sleeve, the filtering assembly being adapted to shift between a filtering position wherein filtering assembly is aligned with the flow port and a non-filtering position wherein the filtering assembly is not aligned with the flow port;
- a first actuator adapted to selectively shift the sliding sleeve of each of the plurality of valves; and
- a second actuator adapted to selectively shift the filtering assembly of each of the plurality of valves.
18. The system of claim 17, wherein the first actuator is one selected from a group consisting of: (i) a drop ball selected to engage the sliding sleeve of each valve, (ii) a dart selected to engage the sliding sleeve of each valve, and (iii) a work string having an outer profile selected to engage the sliding sleeve of each valve and defining a tubular bore.
19. The system of claim 17, wherein the second actuator is one selected from a group consisting of: (i) a drop ball selected to engage the filtering assembly of each valve, (ii) a dart selected to engage the filtering assembly of each valve, and (iii) a work string having an outer profile selected to engage the filtering assembly of each valve and defining a tubular bore.
20. The system of claim 17, wherein the first actuator comprises a first control line connected between a surface location and a piston area above the sliding sleeve of an upper valve among the plurality of valves, and
- wherein the second actuator comprises a second control line connected between a piston area below the sliding sleeve of the upper valve and a piston area above the filtering assembly of a lower valve among the plurality of valves.
21. The system of claim 17, wherein each of the plurality of valves further comprises:
- a removable protector tool for temporarily protecting the filtering assembly.
22. The system of claim 18, wherein the work string further comprises:
- a sealing mechanism arranged above the outer profile, wherein the tubular bore extends below the sealing mechanism.
23. The system of claim 18, wherein the work string further comprises:
- a first sealing mechanism arranged above the outer profile, wherein the tubular bore extends below the sealing mechanism; and
- a removable second sealing mechanism arranged below the outer profile, wherein the tubular bore is temporarily interrupted by the second sealing mechanism.
24. The system of claim 18, wherein the work string further comprises:
- a sealing mechanism arranged below the outer profile, wherein the tubular bore extends below the sealing mechanism.
Type: Application
Filed: Mar 28, 2008
Publication Date: Apr 2, 2009
Applicant: SCHLUMBERGER TECHNOLOGY CORPORATION (Sugar Land, TX)
Inventors: Gary L. Rytlewski (League City, TX), Hugo Morales (Katy, TX), Balkrishna Gadiyar (Katy, TX), John Lassek (Katy, TX), John R. Whitsitt (Houston, TX), Jorge Lopez de Cardenas (Sugar Land, TX), Matthew R. Hackworth (Manvel, TX)
Application Number: 12/058,062
International Classification: E21B 43/14 (20060101); E21B 34/14 (20060101);