Lower Completion Module

Abstract

A technique that is usable with a well includes installing a lower completion module as a unit in the well. The lower completion module includes a flow control mechanism, an annular packer, a sand screen and a flow monitoring device. Either a single unit or a plurality of the units may be installed in the well for zonal isolation and control.

Description

BACKGROUND

The invention generally relates to a downhole modular approach to a lower completion to accomplish such functions as zonal isolation, inflow, outflow, optional monitoring and/or sand management.

A completed well typically includes a lower completion for purposes of communicating and controlling the production of well fluid. The lower completion may include, as an example, packers to isolate various production zones, screens to manage sand production and inflow control devices.

The sand screens limit the production of particulates, or “sand.” The production of sand from the well must be controlled in order to extend the life of the well. One way to control sand production is to install screens in the well and form a substrate around the screens to filter sand from the produced well fluid. A typical sand screen is formed from a cylindrical mesh that is generally concentric with the borehole of the well where well fluid is produced. Gravel is packed in the annular region that surrounds the sand screen. The produced well fluid passes through the gravel, enters the sand screen and is communicated uphole via tubing that is connected to the sand screen.

The inflow control devices regulate the rate at which well fluid flows into the lower completion. Without compensation, the flow distribution along the sand screen is non-uniform, as the pressure drop across the sand screen inherently changes along its length. An uneven well fluid flow distribution may cause various production problems. Therefore, for purposes of achieving a more uniform flow distribution, the inflow devices may be disposed along the length to modify the fluid flow distribution. The inflow control devices may also be used for purposes of shutting off production from a water producing zone, for example.

SUMMARY

In an embodiment of the invention, a technique includes installing a lower completion module as a unit in a well. The lower completion module includes a flow control mechanism, an annular packer, and a sand screen.

In another embodiment of the invention, an apparatus that is usable with a well includes a unit, which includes connectors to connect the unit to a string. The unit also includes an annular packer, a screen and a flow control mechanism.

Advantages and other features of the invention will become apparent from the following drawing, description and claims.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic diagram of a lower completion module according to an embodiment of the invention.

FIG. 2 is a flow diagram depicting a technique to install components in a well according to an embodiment of the invention.

FIGS. 3, 4 and 5 are schematic diagrams of wells illustrating different configurations that may be used with the lower completion module according to embodiments of the invention.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment 10 of a lower completion module in accordance with the invention includes a screen 60, which receives an incoming well fluid flow 80 from a producing zone of a well. In accordance with some embodiments of the invention, the screen 60 circumscribes an inner conduit, or base pipe 100, of the module 10. The screen 60, base pipe 100 and lower completion module 10 in general are coaxial with a longitudinal axis 11. An annular region 90, which is created between the screen 60 and the outer surface of the base pipe 100, receives the incoming well fluid. Unlike some conventional screens, the well fluid does not enter the base pipe 100 through openings that are circumscribed by the screen 60. Instead, the lower completion module 10 includes a flow control mechanism 50, which is longitudinally offset from the screen 60 and controls fluid communication between the annular region 90 and a central passageway 101 of the base pipe 100.

The flow control mechanism 50 may take on numerous forms depending on the particular embodiment of the invention. As examples, the flow control mechanism 50 may be a valve (and therefore, has a controlled, variable cross-sectional flow area) or may be an orifice that has a fixed cross-sectional flow area. The flow control mechanism 50 may be a choke, such as a fixed choke or a variable choke. As another example, the flow control mechanism 50 may be a water or a gas shut-off valve. Regardless of the particular form of the flow control mechanism 50, the mechanism 50 controls communication between the annular region 90 that surrounds the base pipe 100 and the central passageway of the base pipe 100. Thus, when the flow control mechanism 50 allows communication between the annular region 90 and the central passageway 101, the incoming well flow 80 enters the screen 60 and is communicated into the annular space 90 to form an annular flow 93 along the longitudinal axis 11. The longitudinal flow 93 passes through the flow control mechanism 50 and into the central passageway 101 of the base pipe 100 to form a flow 98 to the surface of the well.

In accordance with some embodiments of the invention, the flow control mechanism 50 may be controlled by a wired or a wireless stimulus that is communicated from the surface of the well. In this regard, in accordance with some embodiments of the invention, a control line (not depicted in FIG. 1) may communicate an electrical or a hydraulic signal to the flow control mechanism 50 for purposes of opening and closing the flow control mechanism 50, varying a cross-sectional flow path of the mechanism 50, etc. Alternatively, a wireless stimulus, such as an electromagnetic stimulus, seismic stimulus or pressure pulse (as examples) may be remotely communicated from the surface of the well or other part of the well for purposes of controlling operation of the flow control mechanism 50.

The lower completion module 10 may, in accordance with some embodiments of the invention, include an interface 41 (a sensor-based interface, for example) to detect command-encoded stimuli communicated to the module 10 for purposes of controlling the flow control mechanism 50. In this manner, in some embodiments of the invention, the interface 41 may, in response to the command-encoded stimuli, generate the appropriate signals to control the flow control mechanism 50.

In some embodiments of the invention, the flow control mechanism 50 may employ autonomous control. In this regard, the lower completion module 10 may include an interface 40, which senses one or more parameters of the zone in which the lower completion module 10 is located. As a more specific example, the interface 40 may be attached to sensors, such as temperature and/or pressure sensors and other devices, such as snorkel lines, for purposes of sensing a downhole condition. Thus, the lower completion module 10 may have at least one flow monitoring device to sense one or more parameters, such as a flow rate, a pressure, a temperature, a fluid composition, as few a few examples. In response to the sensed condition(s), interface 40 may generate the appropriate signals to control the flow control mechanism 50 in accordance with the sensor downhole condition(s).

The flow control mechanism 50 may be controlled by performing an intervention in the well, according to some embodiments of the invention. More specifically, a service tool may be deployed into the well for purposes of the intervention. As examples, the service tool may be run into the well on a cable, tractor or pipe; may be dropped into the well (such as when the tool is a dart, ball or rod); or may be pumped down into the well.

In addition to the screen 60 and the flow control mechanism 40, in accordance with some embodiments of the invention, the lower completion 10 includes an annular packer 110. As examples, the annular packer 110 may be an external casing packer; a bladder (such as an inflatable bladder or a metal inflatable bladder, as examples); a packer formed from a swellable material; a packer formed from an ABT hydroform material; a mechanical compression set packer; etc. Regardless of its particular form, the packer 110 may be controlled from the surface of the well; may be controlled by other downhole devices or tools; may be controlled by an electrical signal; may be hydraulically controlled; may be controlled by weight or mechanical movement of a string that is attached to the packer; and/or may be autonomously controlled for purposes of controlling the radial expansion of the packer 110 to form an annular seal in the well. For example, for a packer that contains a sealing element that is formed from a swellable material, the packer 110 expands when sufficient exposure occurs to a particular well fluid or triggering fluid. Alternatively, the radial expansion of the packer 110 may occur in response to a sensed well condition, a wired or wireless stimulus or pressure in the central passageway of the base pipe 100 (as just a few examples). Thus, many variations are possible and are within the scope of the appended claims.

The lower completion module 10 includes connectors on its opposite ends for purposes of releasably connecting the lower completion module 10 to other modules, tubular members, tubular strings, etc., depending on the particular embodiment of the invention. As a more specific example, in accordance with some embodiments of the invention, the lower completion module 10 includes an upper female connector 20, which includes an opening 22 for purposes of receiving a corresponding mating male connector. In general, the upper connector 20 may include internal bonded seals 23 for purposes for forming a sealed connection with the entity that mates with the lower completion module 10 through the connector 20. As examples, the connector 20 may be a J-latch connector, bayonet connector or a threaded connector, depending on the particular embodiment of the invention.

In accordance with some embodiments of the invention, lower completion module 10 includes a lower connector 30, which may be a male-type connector that includes an extension 32 for purposes of forming a corresponding seal with a mating connector of a tubular string, other lower completion module 10, etc. Depending on the particular embodiment of the invention, the lower connector 30 may be a J-latch connector, bayonet connector or a threaded connector, as just a few examples.

In accordance with some embodiments of the invention, the lower completion module 10 has an integrated housing. In this context, an “integrated housing” means a housing that may be formed from one or more housing sections, which are connected together and are designed to be installed as a unit in the well. As an example, in accordance with some embodiments of the invention, the integrated housing may be formed from an upper housing 21 of the upper connector 20; a housing section 64 of the packer 110; the screen 60; and a lower housing 31 of the lower connector 30.

Referring to FIG. 2, to summarize, in accordance with some embodiments of the invention, a technique 150 includes installing a lower completion module in a well. The installation may include installing a screen, flow control mechanism and annular packer as a unit in the well, pursuant to block 152.

The flexibility of the lower completion module permits a wide range of completion configurations. For example, several screen modules 10 may be connected serially together to form a completion assembly in accordance with some embodiments of the invention. FIG. 3 depicts a well 200 in accordance with some embodiments of the invention. The well 200 includes a tubular string 210, which has a section of serially connected lower completion modules 10. The string 10 extends inside a casing string 218 of the well 200 such that the lower completion modules 10 are located in various production zones of the well 200. It is noted that although FIG. 3 depicts the well 200 as being cased, the well 200 may be uncased in accordance with other embodiments of the invention. Additionally, the well 200 may be a subterranean or a subsea well, depending on the particular embodiment of the invention.

Each particular production zone of the well 200 may be formed by one or more lower completion modules 10. The annular packer 110 of the uppermost lower completion module 10 of the zone is set; and likewise, the bottommost lower completion module 10 of the zone may also be set to form a corresponding sealed annular region in between. For each zone, well fluid flows from the surrounding formation through the screen(s) 60 of the corresponding lower completion module(s) 10 and into the central passageway of the string 210.

It is noted that many different embodiments are possible and are within the scope of the appended claims. In this regard, the lower completion module 10 does not necessarily have to be connected to other lower completion modules 10 to fall within the scope of the appended claims. For example, referring to FIG. 4, in accordance with some embodiments of the invention, a well 240 may include a tubular string 242 that is connected to a single lower completion module 10. The well 240 includes a tubular string 242, which may extend through a casing 241 of the well 240, although the well 240 may be cased or uncased, depending on the particular embodiment of the invention. The string 242 includes a lower completion module 10, which is connected in line with the tubular string 242. Below the lower completion module 10 is a packer 250 that forms a connection with the lower completion module 10. Thus, the annular packer 110 of the lower completion module 10 and the packer 250 may be set to form a corresponding sealed annular zone for producing well fluid.

As another example, FIG. 5 depicts a well 300 in accordance with some embodiments of the invention. The well 300 includes a tubular string 310, which extends inside a casing string 308, although the well 300 may be cased or uncased, depending on the particular embodiment of the invention. The string 310 includes a lower completion module 10 that is connected to a conventional screen 320. Thus, the screen 60 of the lower completion module 10 may be in use in conjunction with one or more conventional screens, which are not part of lower completion modules, as described herein.

Although directional terms such as “up,” “down,” “uppermost,” etc. have been used for reasons of convenience for purposes of describing the lower completion module and its associated components and interconnections. These orientations are not necessary to practice the claimed invention. For example, the lower completion module 10 may be located in a horizontal, or lateral wellbore in accordance with other embodiments of the invention. Thus, many variations are contemplated and are within the scope of the appended claims.

While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.

Claims

1. A method usable with a well, comprising:

installing a lower completion module as a unit in the well, the lower completion module comprising a flow control mechanism, an annular packer and a sand screen.

2. The method of claim 1, wherein the lower completion module further comprises a flow monitoring device.

3. The method of claim 1, wherein the act of installing comprises:

installing the sand screen, the flow control mechanism and the annular packer in an integrated housing.

4. The method of claim 1, wherein the act of installing comprises:

forming a connection between a connector of the unit and a tubular string.

5. The method of claim 4, wherein the connector comprises a J-latch connector, a threaded connector or a bayonet connector.

6. The method of claim 1, wherein the act of installing comprises:

connecting the unit to a tubular string.

7. The method of claim 1, wherein the act of installing comprises:

connecting the unit to another unit comprising a flow control mechanism, an annular packer, a flow monitoring device and a sand screen.

8. The method of claim 1, wherein the flow control mechanism comprises a fixed choke, a variable choke or an on/off valve.

9. The method of claim 1, further comprising:

autonomously controlling the flow control mechanism based on a response to a reservoir parameter.

10. The method of claim 1, further comprising:

performing an intervention in the well to control the flow control mechanism.

11. The method of claim 10, wherein the act of performing the intervention comprises an intervention selected from the following:

running a service tool on a cable, tractor or pipe;

dropping the tool into the well; or

pumping the tool down into the well.

12. An apparatus usable with a well, comprising:

a unit comprising connectors to connect the unit to a string, the unit comprising an annular packer, a screen and a flow control mechanism.

13. The apparatus of claim 12, wherein the unit comprises an integrated housing connected to the screen, the flow control mechanism and the annular packer.

14. The apparatus of claim 12, wherein the tubular string comprises a connector to connect to one of the connectors of the unit.

15. The apparatus of claim 14, wherein at least one of the connectors of the unit comprises a J-latch connector, a threaded connector or a bayonet connector.

16. The apparatus of claim 12, wherein the connectors are adapted to connect the unit to a screen.

17. The apparatus of claim 12, wherein the annular packer comprises a swell element, an external casing packer, an ABT hydroform, a mechanical compression set packer, an inflatable bladder or a metal inflate bladder.

18. The apparatus of claim 12, wherein the screen comprises a slotted liner, a stand alone screen, a prepacked screen or a gravel pack screen.

19. The apparatus of claim 12, wherein the flow control mechanism comprises a fixed choke, a variable choke or a shut-off valve.

20. The apparatus of claim 12, wherein the flow control mechanism comprises:

an interface comprising an interface adapted to be controlled via a wireless stimulus, an interface adapted to be controlled in response to a dropped ball or an interface adapted to be controlled in response to a signal communicated over a control line.

21. The apparatus of claim 12, wherein the flow control mechanism is adapted to be autonomously controlled.