communications module to alternate gravel packaging from alternate path and method to complete a wel

专利摘要:
communications module for alternating gravel packaging of alternate path and method for completing a well. a communication module and methods for downhole operations, useful for producing hydrocarbon fluids from a well, including at least one alternative flow channel and an electrical circuit. generally, the electrical circuit is pre-programmed to (i) receive a signal, in response to the received signal, supply a trigger command signal. the communications module also has a transponder. the communication module allows a downhole tool to be activated within a well completion interval, without providing an electrical line or working pipeline from the surface. the tool can be activated in response to the reading of a reading tool, or in response to a signal emitted in the well by a well bottom support, or labeled for identification.
公开号:BR112013008056B1
申请号:R112013008056
申请日:2011-11-02
公开日:2020-04-07
发明作者:S Yeh Charles；B Entchev Pavlin；M Angeles Boza Renzo；J Moffett Tracy
申请人:Exxonmobil Upstream Res Co；
IPC主号:

专利说明:

COMMUNICATIONS MODULE TO ALTERNATE ALTERNATIVE PATH PACKAGING PACKAGING AND METHOD TO COMPLETE A WELL
REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application 61 / 423,914, filed on December 16, 2010.
BACKGROUND OF THE INVENTION [0002] This section is intended to introduce various aspects of the art, which can be associated with exemplary embodiments of the present description. This discussion is believed to assist in providing a context to facilitate a better understanding of particular aspects of the present invention. Therefore, it should be understood that this section should be read in this light and not necessarily as admissions to the prior art.
FIELD OF THE INVENTION [0003] The present invention relates to the field of well conclusions. More specifically, the present invention relates to wireless communication and control systems within a well. The application also refers to the remote activation of tools in relation to wells that have been completed using gravel conditioning.
DISCUSSION OF THE TECHNOLOGY [0004] When drilling oil and gas wells, a well is formed using a drill bit that is pressed downwards on a lower end of a drilling column. After drilling to a predetermined depth, the drill string and drill are removed and the well is lined with a column of liners. An annular area is thus formed between the coating column and
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2/47 training. A cementation operation is typically conducted in order to fill or "squeeze" the annular area with cement. The combination of cement and casing tubes strengthens the well and facilitates the isolation of certain areas of the formation behind the casing tubes.
[0005] It is common to place several columns of casing tubes, progressively having smaller outside diameters, inside the well. The drilling process and then gradually cementing smaller columns of casing tubes is repeated several times until the well has reached full depth. The column of final coating tubes, referred to as a production coating, is cemented into position and drilled. In some instances, the column of finished liner tubes is a liner, i.e., a column of liner tubes that is not tied back to the surface.
[0006] As part of the completion process, a wellhead is installed on the surface. The wellhead controls the flow of production fluids to the surface, or the injection of fluids into the well. Collection and processing equipment, such as tubes, valves and separators, are also provided. Production operations can then begin.
[0007] It is sometimes desirable to leave the bottom part of a well open. In open-hole conclusions, a production liner is not extended through the production zones and drilled; undoubtedly, production zones are left uncoated or “open”. A production column or “pipe” is then positioned inside the well, extending downwards under the last column of casing tubes and through a subsurface formation.
[0008] There are certain advantages to open-hole versus versus coated-hole conclusions. First, because the open tube findings did not have
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3/47 drilling tunnels, the formation fluids can converge to the well radially 360 degrees. This has the benefit of eliminating the additional pressure drop associated with the converging radial flow and then the linear flow through the start-filled drill tunnels. The reduced pressure drop, associated with an open-hole completion, virtually guarantees that it will be more productive than a coated, unstimulated hole of the same formation.
[0009] Second, open-hole techniques are often less expensive than coated hole conclusions. For example, the use of gravel packaging eliminates the need for cementation, drilling and post-drilling cleaning operations.
[0010] A common problem in open-hole conclusions is the immediate exposure of the well to the surrounding formation. If the formation is not consolidated or heavily sandy, the flow of production fluids into the well can carry particles from the formation with it, e.g. sand and fines. Such particles can be erosive for bottom-of-well production equipment and for pipes, valves and surface separation equipment.
[0011] To control the invasion of sand and other particles, sand control devices can be used. Sand control devices are usually installed at the bottom of the pit through formations, to retain solid materials larger than a certain diameter, while allowing fluids to be produced. A sand control device typically includes an elongated tubular body, known as a base tube, having numerous notched openings. The base tube is then typically wrapped or otherwise covered with a filter medium, such as a screen or wire mesh. This is referred to as a sand sieve.
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4/47 [0012] To increase sand control devices, particularly in open-hole finishes, it is common to install a gravel package. Packing gravel in a well involves placing gravel or other particulate matter around the sand control device after the sand control device is suspended or otherwise placed in the well. To install a gravel package, a particulate material is supplied at the bottom of the well by means of a conveyor fluid. The carrier fluid with the gravel together forms a gravel sludge. The mud dries in position, leaving a circumferential wrapping of gravel. The gravel not only helps in filtering particles, but also helps to maintain the integrity of the formation.
[0013] In an open-hole gravel package finish, the gravel is positioned between a sand sieve, which surrounds a perforated base tube and a wall surrounding the well. During production, the formation fluids flow from the underground formation, through the gravel, through the sieve and into the inner base tube. The base tube thus serves as a part of the production column.
[0014] In some cases, a bundle of gravel is placed along a finishing range of a coated hole. This is particularly advantageous in unconsolidated sandstone formations. In this example, a sand sieve surrounding a perforated base tube is placed inside the well along the subsurface formation and a gravel pack is installed between the sand sieve and the surrounding perforated production liner tubes. The resulting gravel package restricts the invasion of sand and fines.
[0015] A problem historically encountered with the packing of gravel is that an inadvertent loss of fluid carrying the mud during the process of
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5/47 supply can result in premature formation of sand bridges at various locations throughout the hole-open intervals. For example, in an inclined production interval or an interval having an enlarged or irregular borehole, poor gravel distribution can occur due to premature loss of fluid carrying the gravel sludge into the formation. The loss of fluid can then cause voids to form in the gravel package. Thus, a complete gravel package from the base to the top is not achieved, leaving the well exposed to sand and fines infiltration.
[0016] The problem of sand bridge formation has been discussed through the use of alternative path technology, or “APT”. The alternative path technology employs bypass tubes (or bypasses) that allow the gravel mud to deviate from the sand bridges or selected areas along the well. Such alternative path technology is described, for example, in US Patent No. 5,588,487, entitled “Tool for Blocking Axial Flow in Gravel-Packed Well Annulus” and PCT Publication No. W02008 060479, entitled “Wellbore Method and Apparatus for Completion , Production and Injection ”, each of which is incorporated here by reference in its entirety. An additional reference that discusses alternative path technology is M.D. Barry et al., “Open-hole Gravel Packing with Zonal Isolation”, Document SPE No. 110.460 (November 1007).
[0017] Regarding sand sieves with an alternative path, it was proposed to use control lines and sensors. US Patent No. 7,441,605, entitled “Optical Sensor Use in Alternate Path Gravel Packing with Integral Zonal Isolation”, offers devices and methods for monitoring downhole conditions, while conducting hydrocarbon production within an open borehole. across multiple zones. There, a production pipe column unit is provided
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6/47 with a plurality of packers ostensibly suitable for sealing between multiple individual downhole zones. Packers are placed using hydraulic fluid pressure present inside the bore of the production pipe column. In addition to the packers, the production tube column includes production nozzles having perforated screens for removing debris from the fluids produced. One or more lines of optical sensors are arranged on the outside of the screens. The sensor lines are arranged through the packers using a through-pass system to provide uninterrupted reading line (s) for the well surface. This allows temperature, pressure or other well conditions to be monitored on the surface of each of the individual zones of interest. In addition, the hydraulic control lines are arranged on the outside of the sieve to facilitate the installation of fiber optics after positioning.
[0018] There are additional references that discuss control lines, including fiber optic lines, in an open hole finish.
[0019] There are additional references that discuss control lines, including fiber optic lines, in an open-hole finish. These include U.S. Patent No. 7,243,715, U.S. Patent No. 7,431,085; U.S. Patent No. 6,848,510; U.S. Patent No. 6,817,410; and U.S. Patent No. 6,681,854. However, these references require a physical path to provide communication from the surface to a rock bottom location, or vice versa. In subsea or extended wells, the complexity and reliability of such finishes becomes a concern.
[0020] Therefore, there is a need for an improved sand control system, which provides not only alternative flow path technology for gravel boxing, but also a communication and communication system.
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7/47 improved control. In addition, a wireless system is required with respect to sand control operations, particularly with alternate path sand screens.
SUMMARY OF THE INVENTION [0021] A communication module for downhole operations is provided here. The communication module is useful in relation to the production of hydrocarbon fluids from a well. The well can be completed with a production liner or it can be an open-bore well. The well has a lower end defining a finishing interval, which can extend through one, two or more subsurface intervals.
[0022] In one embodiment, the communication module provides an internal mandrel. The internal mandrel is preferably dimensioned according to a base tube of a sand control device. Preferably, the inner body is made of a non-metallic material, such as ceramic or plastic.
[0023] The communication module can also comprise an external cover. The outer cover is circumferentially arranged around the inner mandrel. The outer cover preferably does not function as a filter medium, but freely allows the flow of formation fluids through it. The external cover can be concentric or eccentric to the internal mandrel.
[0024] The communication module also includes at least one alternative flow channel. The alternate flow channel represents one or more bypass tubes, which are configured to provide a route for gravel sludge during a gravel packing operation. The gravel sludge will first flow into the annulus between the communication module and the surrounding well. After that, the fluid phase of the sludge leaks into the formation of nearby reservoir or sieves
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8/47 of sand, and an annular package is deposited in the annular ring surrounding the communication module. The sludge will then bypass the communication module through alternating flow channels, to provide gravel storage under the communication module.
[0025] The alternating flow channels can be, for example, a longitudinal ring between the external and internal mandrels. The alternating flow channels can contain both transport tubes and packing tubes, where the packing tubes are equipped with flow holes opening to the annular crown of the well to exit the mud. The alternating flow channels can also be, for example, transport tubes arranged between the inner mandrel and the surrounding outer shell. Alternatively, the alternating flow channels may be a longitudinal annulus between an outer cover and an inner mandrel.
[0026] The communication module also has a transponder. The transponder (i) receives a signal and (ii) in response to the received signal, sends a separation instruction signal. The communication module also has an electrical circuit. In general, the electrical circuit is programmed to (i) receive a signal and, in response to the received signal, supply a trigger command signal.
[0027] In addition, the communication module includes a control line. The control line is configured to reside entirely within the subsurface finishing range of the well and is not attached to the surface. The control line serves to carry a trigger command signal to a downhole tool. The downhole tool can be, for example, a sliding sleeve, a valve or a plug. The control line operates in response to the command signal provided by the pre-programmed electrical circuit.
[0028] The communication module is configured to connect to a joint
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9/47 tubular well. In one aspect, the tubular joint comprises a joint for a sand control device. The sand control device will have a sand screen equipped with alternative path channels.
[0029] In one embodiment, the transponder is configured to (i) receive a signal from a downhole vehicle and, (ii) in response to the received signal, send a separate instruction signal to the electrical circuit preprogrammed to trigger a downhole tool.
[0030] In one aspect, the communication module further comprises a reading device. The reading device can be a pressure gauge, a flow meter, a temperature gauge, a sand detector, an in-line tracking analyzer, a compaction stress detector, or combinations thereof. The reading device is in electrical communication with the electrical circuit. Optionally, the electrical circuit is programmed to send a command signal to the control line to activate the downhole tool, in response to a reading selected by the reading device.
[0031] In another aspect, the electrical circuit receives and writes readings from the reading device. The electrical circuit is pre-programmed to send a signal to the transponder carrying the recorded readings. The transceiver, in turn, is programmed to (i) receive the recorded readings from the electrical circuit and, (ii) in response to the recorded readings received, wirelessly transmit the recorded readings to the downhole vehicle.
[0032] A method for completing a well is also described here. The method is useful in the production of hydrocarbon fluids from a well. The well has a lower end defining a finishing interval. The finishing interval can be extended through one, two or more
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10/47 subsurface.
[0033] In one embodiment, the method includes connecting a communication module with a tubular joint. The communication module can be according to the communication module described above. The module will at least include alternate flow channels, configured to provide an alternate flow path for a gravel sludge to partially deviate from the communication module during a gravel packaging procedure. This means that, after the gravel is densified in the annular crown between the communication module and the surrounding well, most of the mud will deviate from the communication module to provide gravel density under the communication module.
[0034] The module will also have a control line. Beneficially, the control line is configured to reside entirely within the well finish range. The control line carries a trigger command signal to a downhole tool within the well.
[0035] The method will also include running the communication module and the tubular joint connected inside the well. The tubular joint may comprise a joint for a sand control device. The sand control device will have a sand screen with alternating flow channels. Alternatively, the tubular joint can be a plug with alternative path channels that can be placed inside the well before a gravel thickening operation begins. The communication module can also be built or embedded within a tubular joint.
[0036] The method also includes positioning the communication module and the tubular joint within the finishing range of the well. Then, the method includes injecting a gravel slurry into an annular region between the communication module and the surrounding well, as well as between the tubular joints and the surrounding well. THE
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11/47 gravel sludge travels through at least one alternative flow channel within the tubular joints to allow the gravel sludge to at least partially deviate from any premature sand bridges or zonal isolation of the annular crown. In this way, the crushing of gravel under the communication module is provided.
[0037] Preferably, the well is completed for the production of hydrocarbon fluids. The method also includes production fluids from at least one subsurface interval over the well finishing interval for a period of time.
[0038] In one embodiment, the control line contains an electrical line. In this example, the method may also comprise sending a signal from the electrical circuit through the electrical line to drive the downhole tool. The downhole tool can be, for example, a sliding sleeve, a plug or a valve.
[0039] The method preferably operates in conjunction with a downhole vehicle. The downhole vehicle is essentially an information tag, which is pumped, dropped, or otherwise released into the well. Information can flow from the downhole vehicle to the transponder or from the transponder to the downhole vehicle. In one event or another, information is beneficially exchanged within the well during well operations without the need for an electrical line or working piping.
[0040] In one aspect, the transponder is programmed to (i) receive a wireless signal from the downhole vehicle and, (ii) in response to the received signal, send a separate instruction signal to the electrical circuit pre-programmed to activate the downhole tool.
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12/47 [0041] The communication module can include a reading device. The reading device can be, for example, a pressure gauge, a flow meter, a thermometer, an in-line plotter analyzer. The reading device is in electrical communication with the electrical circuit. In this example, the method also includes recording a reading by the reading device in the electrical circuit. The electrical circuit can then send a signal from the electrical circuit to the control line to drive the downhole tool in response to a reading selected by the reading device. Alternatively, the electrical circuit can send its signal to the transmitter-receiver, which in turn sends a signal containing the readings recorded to the downhole vehicle.
[0042] A separate method for driving a downhole tool in a well is also provided here. The well again has a lower end defining a finishing interval. The finishing range can be an open hole part.
[0043] In one embodiment, the method includes running a communication module and a tubular joint connected inside the well. The communication module can be according to the communication module described above. The module will at least include alternate flow channels, configured to allow a gravel sludge to partially deviate from the blocked annular crown adjacent to the communication module during a gravel conditioning procedure. In this way, the gravel packaging is provided under the communication module. The module will also have a control line configured to reside entirely within the open-hole (or other) part of the well. The control line carries a trigger command signal to a downhole tool within the well.
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13/47 [0044] The method also includes positioning the communication module and the tubular joint within the finishing range of the well. Preferably, the tubular joint is part of a sand control device with alternating path channels. The sand control device will have a filtering screen. The method will also include injecting a gravel slurry into an annular region formed between the sand control device and the surrounding well. The sand control device will also have at least one alternative flow channel to allow the gravel sludge to at least partially deviate from the joint of the sand control device during the gravel packing operation in the event that the crown annuls the downstream be blocked by the premature sand bridge or a zonal isolation device.
[0045] After the communication module and the tubular joint are positioned, the method includes releasing a first downhole vehicle into the well. The downhole vehicle is essentially an information tag that is pumped, dropped, or otherwise released into the well. In this arrangement, the rock bottom vehicle emits a first frequency signal. Thus, information flows from the downhole vehicle to the transponder inside the well. This can occur during well operations without the need for an electric line or a working column.
[0046] The method also includes reading the first frequency signal on the transmitter. In response to the first frequency signal, a first instruction signal is sent by the transponder to the electrical circuit.
[0047] The method also comprises sending a first corner surface through the electrical circuit. This is done in response to the first instruction signal to trigger a downhole tool. The activation of the downhole tool
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14/47 may comprise (i) moving a sliding glove to close the production of a selected zone within the finishing range, (ii) moving a sliding glove to open the production of a selected zone within the finishing range, (iii) or install a shutter.
[0048] Preferably, the communication module employs RFID technology. In such an embodiment, the pre-programmed electrical circuit is an RFID circuit. In addition, the downhole vehicle is an RFID tag that emits a radio frequency signal, while the transceiver is an RF antenna.
[0049] Alternatively, the communication module employs acoustic technology. In such an example, the downhole vehicle comprises an acoustic frequency generator. The transponder then comprises an acoustic antenna that receives acoustic signals from the downhole vehicle and, in response, sends an electrical signal to the pre-programmed electrical circuit.
[0050] In one embodiment, the method uses a second downhole vehicle. In the example, the method includes releasing a second downhole vehicle into the well. The second downhole vehicle emits a second frequency signal. The second frequency signal is also read at the transponder. In response to the second frequency signal, a second instruction signal is sent by the transponder to the electrical circuit. Then, in response to the second instruction signal, a second command signal is sent by the electrical circuit to activate a downhole tool.
[0051] The present description also provides a method for monitoring conditions in a well. The well has a lower end defining a finishing interval. The finishing range can be along a production coating section, or within a hole-open part. Monitoring
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15/47 occurs during hydrocarbon production operations, after a gravel conditioning operation has been conducted.
[0052] In one embodiment, the method includes running a communication module and a tubular joint connected inside the well. The communication module can be according to the communication module described above. The module will at least include alternate flow channels, configured to allow the gravel sludge to partially deviate from the dome during a gravel conditioning procedure. In this way, the gravel packaging is provided under the communication module.
[0053] The communication module will also have a control line. Beneficially, the control line is configured to reside entirely within the open bore part of the well. The control line carries a trigger command signal to a downhole tool within the well.
[0054] The method also includes positioning the communication module and the tubular joint inside the open hole part of the well. Preferably, the tubular joint is part of a sand control device. The sand control device will have a filtering screen and will also have at least one alternative flow channel. The method will then also include injecting a gravel slurry into an annular region formed between the sand control device and the open hole portion surrounding the well. The sand control device will also have at least one alternative flow channel to allow the gravel sludge to at least partially deviate from the joint of the sand control device during the gravel conditioning operation.
[0055] The method also includes producing hydrocarbon fluids through the open-bore part of the well. During production, the method includes reading a background condition from
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16/47 well. The drilling tool condition can be, for example, temperature, pressure, flow rate or other parameters. Reading takes place using a reading device that is in electrical communication with an electrical circuit. The method then includes referring the downhole condition readings read by the reading device to the electrical circuit.
[0056] The method also includes the steps of:
release a downhole vehicle into the well;
send the readings from the electrical circuit to the transmitter-receiver;
send the transmitter-receiver readings to the downhole vehicle; recover the downhole vehicle from the well; and download recorded readings from the downhole vehicle for analysis.
[0057] Different means can be used to release the downhole vehicle. In one example, releasing the downhole vehicle comprises releasing the downhole vehicle from the open hole portion of the well at or below the communication module. This arrangement may include the use of a separate information tag. Thus, the method may include pumping a tag from a surface into the well, the tag emitting a first frequency signal, reading the first frequency signal on the transponder and, in response, reading the first frequency signal, releasing the downhole vehicle inside the well.
[0058] Alternatively, releasing the downhole vehicle may mean pumping the downhole vehicle from a surface into the well and down to the communication module.
BRIEF DESCRIPTION OF THE DRAWINGS [0059] So that the way in which the present inventions can be better understood, certain illustrations, diagrams and / or flowcharts are attached
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17/47 here. We note, however, that the drawings illustrate only selected embodiments of the inventions and are not, therefore, to be considered scope-limiting, since the inventions may admit other equally effective embodiments and applications.
[0060] Figure 1 is a cross-sectional view of an illustrative well. The well was drilled through three different subsurface intervals, each interval being under formation pressure and containing fluids.
[0061] Figure 2 is an enlarged cross-sectional view of a hole-open finish of the well in Figure 1. The hole-open finish at the depth of the three illustrative intervals is most clearly seen.
[0062] Figure 3A provides a cross-sectional view of a sand control device, in one embodiment. Bypass tubes are seen outside a sand sieve to provide an alternative flow path for particulate sludge.
[0063] Figure 3B provides a cross-sectional view of a sand control device, in an alternative embodiment. Bypass tubes are seen inside a sand sieve, to provide an alternative flow path for particulate mud.
[0064] Figure 4A is a cross-sectional view of a well with an associated sand control device in it. The transport tubes extend over the sand sieve.
[0065] Figure 4B is a cross-sectional view of one of the sand control devices in Figure 4A, taken through line 4B-4B in Figure 4A. The transport tubes and packaging tubes are seen outside the sand sieve.
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18/47 [0066] Figure 5A is a perspective view of a communication module according to the present inventions, in an embodiment. The communication module has a pre-programmed electrical circuit and a communication device for transmitting or receiving commands from a downhole vehicle.
[0067] Figure 5B is a cross-sectional view of the communication module of Figure 5A, taken through line 5B-5B. An optional motor and associated control line are shown, along with the transport tubes and conditioning tubes for transporting gravel sludge.
[0068] Figure 6 is a perspective view of a communication module, in an alternative embodiment. Here, the communication module employs radio frequency identification tags. The pre-programmed electrical circuit is an RFID circuit and the communication device is an RFI antenna that communicates with an RFID tag.
[0069] Figure 7 is a flow chart that provides steps that can be used, in one embodiment, to complete a well. The well has a lower end defining a hole-open part. The method uses a communication module having alternative flow channels.
[0070] Figure 8 is a flowchart that provides steps that can be used, in one embodiment, to drive a downhole tool within a well. The well has a lower end defining an open hole part.
[0071] Figure 9 is a flow chart that provides steps for a method to monitor conditions in a well. The well has a lower end defining an open hole part.
DETAILED DESCRIPTION OF CERTAIN WAYS OF ACHIEVEMENTS [0072] Definitions
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19/47 [0073] As used herein, the term "hydrocarbon" refers to an organic compound that includes mainly, if not exclusively, the elements hydrogen and carbon. Hydrocarbons generally fall into two classes: aliphatic or straight chain hydrocarbons and cyclic or closed ring hydrocarbons, including cyclic terpenes. Examples of hydrocarbon-containing materials include any form of natural gas, oil, coal and bitumen, which can be used as a fuel or upgraded to a fuel.
[0074] As used herein, the term "hydrocarbon fluids" refers to a hydrocarbon or mixtures of hydrocarbons that are gases or liquids. For example, hydrocarbon fluids can include a hydrocarbon or mixtures of hydrocarbons that are gases or liquids under formation conditions, processing conditions or ambient conditions (15 ° C and pressure at 1 atm). Hydrocarbon fluids can include, for example, oil, natural gas, coal bed methane, shale oil, pyrolysis oil, pyrolysis gas, a coal pyrolysis product and other hydrocarbons that are in a gaseous or liquid state.
[0075] As used herein, the term "fluid" refers to aces, liquids and combinations of gases and liquids, as well as combinations of gases and solids, and combinations of liquids and solids.
[0076] As used here, the term "subsurface" refers to geological strata occurring below the earth's surface.
[0077] The term "subsurface gap" refers to a formation or a part of a formation in which the formation fluids may reside. The fluids can be, for example, hydrocarbon liquids, hydrocarbon gases, aqueous fluids or combinations thereof.
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20/47 [0078] As used here, the term “well” refers to a hole in the subsurface, made by drilling or inserting a conduit inside the subsurface. A well may have a substantially circular cross-section, or another cross-sectional shape. As used herein, the term “well”, when referring to an opening in the formation, can be used interchangeably with the term “well”.
[0079] The term "tubular member" refers to any tube, such as a set of casing tubes, a part of a casing or a set of tubes.
[0080] The term "sand control device" means any elongated tubular body, which allows an influx of fluid into an inner hole or a base tube, while filtering sand, fines and granular debris from a surrounding formation.
[0081] The term "alternative flow channels" means any collection of distribution tubes and / or bypass tubes, which provide fluid communication through or around a downhole device, such as a sand sieve, a shutter, or a communication module, to allow a gravel sludge to at least partially deviate from the device in order to obtain complete gravel packing from an annular region under the device.
DESCRIPTION OF SPECIFIC EMBODIMENTS [0082] The inventions are described here with respect to certain specific embodiments. However, to the extent that the following detailed description is specific to a particular embodiment or a particular use, this is intended to be illustrative only and is not to be construed as limiting the scope of the inventions.
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21/47 [0083] Certain aspects of the inventions are also described in relation to various figures. In some of the figures, the top of the drawing page is intended to be towards the surface and the base of the drawing page towards the base of the well. Although wells are commonly finished in substantially vertical orientation, it is understood that the wells can also be tilted and or even horizontally completed. When the descriptive terms "top and bottom" or "top" and "bottom" or "bottom" are used with reference to a design or in the claims, they are intended to indicate relative location of the design page or with respect to claim terms , and not necessarily orientation on the ground, since the present inventions are useful, no matter how the well is oriented.
[0084] Figure 1 is a cross-sectional view of an illustrative well 100. Well 100 defines a hole 105 that extends from a surface 101 and into the subsurface of the earth 110. Well 100 is finished to have a portion open-hole 120 at a lower end of well 100. Well 100 was formed for the purpose of producing hydrocarbons for commercial sale. A column of production tubes 130 is provided in bore 105 to transport production fluids from the open-bore part 120 to surface 101.
[0085] Well 100 includes a well tree, shown schematically in 124. Well tree 124 includes a confining valve 126. Shut-off valve 126 controls the flow of production fluids from well 100. In addition, a valve if subsurface safety 132 is provided to block the flow of fluids from production piping 130 in the event of a rupture or catastrophic event above subsurface safety valve 132. Well 100 can optionally have a pump (not shown) inside or exactly on top of
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22/47 borehole part 120, to artificially raise production fluids from the borehole part 120 to the shaft tree 124.
[0086] Well 100 has been completed by placing a series of tubes within subsurface 110. These tubes include a first column of casing tubes 102, sometimes known as surface casing tubes or a conductor. These tubes also include at least a second 104 and a third 106 column of casing tubes. These lining tube columns 104, 106 are intermediate lining tube columns, which provide support for the walls of the well 100. The intermediate lining tube columns 104, 106 can be suspended from the surface or can be suspended by a next column. of higher lining tubes, using an expandable lining or lining hook. It is understood that a column of tubes that does not extend back to the surface is usually referred to as a "coating".
[0087] In the illustrative well arrangement of Figure 1, the column of intermediate lining tubes 104 is suspended by surface 101, while the column of lining tubes 106 is suspended by a lower end of the column of lining tubes 104. The columns bottom casing tube 106 ends at 134. Additional intermediate casing tube columns (not shown) can be employed. The present inventors are not limited to the type of coating tube architecture used.
[0088] Each column of casing tubes 102, 104, 106 is placed in position through cement 108. Cement 108 isolates the various formations of subsurface 110 of well 100 and between them. The cement 108 extends from the surface 101 to a depth “L” at a lower end of the column of coating tubes
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23/47
106. It is understood that some columns of intermediate lining tubes may not be fully cemented.
[0089] An annular region 204 is formed between the production pipe 130 and the surrounding casing tube column 106. A plug 206 seals the annular region 204 near the lower end "L" of the casing tube column 106.
[0090] In many wells, a column of final lining tubes, known as the production lining tube, is cemented into position at a depth where the subsurface production intervals reside. For example, a production liner (not shown) can be suspended by the lower end 134 of the column of liner tubes 106. The production liner would extend substantially to a lower end 136 (not shown in Figure 1, but shown in Figure 2) of the open hole part 120 of the well 100. However, the illustrative well 100 is completed as an open hole part. Accordingly, well 100 does not include a column of final liner tubes along borehole 120.
[0091] In the illustrative well 100, the open hole part 120 crosses three different subsurface intervals. These are indicated as upper range 112, intermediate range 114 and lower range 116. Upper range 112 and lower range 116 may, for example, contain valuable oil deposits sought for production, while intermediate range 114 may contain primary water or another aqueous fluid within its porous volume. This may be due to the presence of native water zones, high layers of permeability, natural fractures connected with an aquifer or fingering of injection wells. In this example, there is a likelihood that water will invade well 100. In addition
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In addition, undesirable condensable fluids, such as hydrogen sulphide gas or acid gases can invade well 100.
[0092] Alternatively, the upper 112 and intermediate 114 ranges may contain hydrocarbon fluids sought to be produced, processed and sold, while the lower range 116 may contain some oil together with ever-increasing amounts of water. This may be due to the formation of a cone, which is an elevation of hydrocarbon-water contact near the well. In this example, there is again the possibility that water will invade well 100.
Alternatively, the upper 112 and lower 116 ranges may be producing hydrocarbon fluids from a sand or other permeable rock matrix, while the intermediate range 114 may represent a non-permeable shale or otherwise be substantially fluid impervious.
[0094] In any of these events, it is desirable that the operator isolate selected zones or intervals. In the first example, the operator will want to isolate the intermediate range 114 from the production tube column 130 and the upper range 112 and lower range 116, so that mainly hydrocarbon fluids can be produced through well 100 and to surface 101. In the second example , the operator will eventually want to isolate the lower gap 116 of the production tube column 130 and the upper gap 112 and intermediate 114, so that mainly hydrocarbon fluids can be produced through well 100 and to surface 101. In the third example, the The operator will want to isolate the upper range 112 from the lower range 116, but there is no need to isolate the intermediate range 114. Solutions to these needs in the context of an open-hole finish are provided here and are demonstrated more fully with respect to the procedure drawings.
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25/47 [0095] Regarding the production of hydrocarbon fluids from a well having a hole-open finish, it is not only desirable to isolate selected intervals, but also to limit the influx of sand and other fine particles. In order to avoid the migration of the formation particles into the production tube column 130 during operation, the sand control devices 200 were placed inside the well 100. These are described more fully below with respect to Figure 2 and the Figures 4A and 4B.
[0096] Referring now to Figure 2, this is an enlarged cross-sectional view of the open hole part 120 of well 100 of Figure 1. The open hole part 120 and the three intervals 112, 114, 116 are most clearly seen . The upper 210 'and lower 210' shutter units are also more clearly visible near the upper and lower limits of the intermediate range 114, respectively. Finally, sand control devices 200, along each of the intervals 112, 114,116, are shown.
[0097] Sand control devices 200 contain an elongated tubular body, referred to as a base tube 205. The base tube 205 is typically composed of a plurality of tube joints. The base tube 205 (or each tube joint comprising the base tube 205) typically has small perforations or cracks, to allow the influx of production fluids.
[0098] Sand control devices 200 also contain a filter medium 207. The filter medium typically defines a coiled metal material or otherwise placed radially around the base tubes 205. Filter medium 207 is preferably a combination of wire mesh screens or coiled wire screens, fitted around the 205 base tube. The mesh or screens serve as filters 207, to prevent the influx of sand or other particles to stop
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26/47 inside the cracked (or perforated) pipe 205 and the production pipe 130.
[0099] In addition to the sand control devices 200, well 100 includes one or more packaging units 210. In the illustrative arrangement of Figures 1 and 2, well 100 has an upper packaging unit 210 'and a lower packaging unit 210 ”. However, additional packaging units 210 or just one packaging unit 210 can be used. Packing units 210 ’, 210 ″ are uniquely configured to seal an annular region (seen at 202 of Figure 2) between the various sand control devices 200 and a surrounding wall 201 of open hole part 120 of well 100.
[00100] With reference to the packaging units themselves, each packaging unit 210 ’, 210” contains at least two packers. These represent an upper packer 212 and a lower packer 214. Each packer 212, 214 has an expandable part or element made of an elastomeric or thermoplastic material capable of providing at least a temporary fluid seal against the surrounding well wall 201.
[00101] It is understood that the packaging units 210 ', 210 ”are merely illustrative; the operator can choose to use only a single packer. In either example, it is preferred that the packer is able to withstand the pressures and loads associated with a gravel packing process. Typically, such pressures are about 2000 psi to 3000 psi (140.6 kg / cm ² to 210.9 kg / cm ² ). [00102] The upper 212 and lower 214 packaging elements are placed shortly before a gravel package installation process. Packing elements 212, 214 are preferably placed by shearing a shear pin and sliding a release sleeve along an internal mandrel. The upward movement of the displacement tool (not shown) allows
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27/47 that packers 212, 214 are activated in sequence. The lower packer 214 is activated first, followed by the upper packer 212 when the displacement tool is pulled upward through the respective internal mandrels.
[00103] An intermediate packaging element 216 can also optionally be provided in the packaging units 210 ', 210 ". The expandable packaging element 216 assists in long-term sealing. The expandable packaging element 216 can be attached to the outer surface of mandrel 211. The expandable packaging element 216 is allowed to expand over time when contacted by hydrocarbon fluids, formation water, or any chemical that can be used as the driving fluid. When the packaging element 216 expands, it forms a fluid seal with the surrounding area, e.g. , range 114. In one aspect, a sealing surface of the expandable pack element 216 is about 5 feet (1.5 meters) to 50 feet (15.2 meters) in length; and, more preferably, about 3 feet (0.9 meters) to 40 feet (12.2 meters) in length.
[00104] Q Using a packer (or optionally a multi-packer unit) in a gravel packaging finish helps to control and manage fluids produced by different zones. In this regard, a packer allows the operator to seal a production or injection interval, depending on the function of the well.
[00105] The packers will incorporate alternative flow channels to bypass the gravel sludge during a gravel packing operation. In addition, sand control devices 200 will have alternative flow channels. Figures 3A and 3B provide cross-sectional views of sand screens with alternative flow channels, in different embodiments.
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28/47 [00106] First, Figure 3A provides a cross-sectional view of a 200A sand control device, in one embodiment. In Figure 3A, a split (or perforated) 205 base tube is seen. This is according to the base tube 205 of Figures 1 and 2. The central hole 105 is shown inside the base tube 205 to receive production fluids during production operations.
[00107] An outer mesh 220 is disposed immediately around the split or perforated base tube 205. The outer mesh 220 preferably comprises a wire mesh or wires helically wound around the base tube 205 and serves as a sieve. In addition, bypass tubes 225 are placed radially and equidistant around the outer mesh 220. This means that the sand control device 200A provides an external embodiment for the bypass tubes 225. The bypass tubes serve as alternative flows to supply gravel sludge in addition to any annular zone isolation or premature sand bridges that might form.
[00108] The configuration of the 200A sand control device can be modified. In this regard, the bypass tubes 225 can be moved internally through the screen 220.
[00109] Figure 3B provides a cross-sectional view of a 200B sand control device, in an alternative embodiment. In Figure 3B, the split (or perforated) base tube 205 is seen again. This is according to the base tube 205 of Figures 1 and 2. The central bore 105 is shown inside the base tube 205 to receive production fluids during production operations.
[00110] The bypass tubes 225 are placed radially and equidistant around the base tube 205. The bypass tubes 225 reside immediately around the base tube 230 and within a surrounding sieve 220. This means that the control device 200B sand filter provides an internal embodiment for
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29/47 diversion tubes 225.
[00111] An annular region 215 is created between the base tube 205 and the surrounding outer mesh or screen 220. The annular region 215 accommodates the influx of production fluids into a well. The outer mesh 220 is supported by a plurality of support ribs extending radially 222. The ribs 222 extend through the annular region 215.
[00112] Figure 4A shows a side view in cross section of a well 400. The well 400 is generally according to the well. Figure 4A shows mainly the lower part of well 400, which was completed as an open-hole. The open-hole part extends to the lower end 136.
[00113] The sand control devices 200 were placed along the bottom 120 of the well 400. The sand control devices 200 are joined together. In addition, a single packer 450 is provided along the sand control devices 200. The packer 450 has been placed against the surrounding well wall 201.
[00114] Figure 4B is a cross-sectional view of one of the sand control devices 200 of Figure 4A, taken through line 4B-4B. In this view, a split or perforated base tube 205 for the sand control device 200 is seen. The base tube 205 defines a central hole 105, through which production fluids can flow. A sand sieve 220 is disposed immediately around the base tube 205. The sand sieve 220 can include multiple segments of wire, mesh sieve, wire wrap or other filtering means to avoid a predetermined particle size.
[00115] Well 400 has not yet been packed with gravel. In order to transport the gravel sludge in a gravel packing operation,
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Devsio tubes 425 are provided along each of the sand sieves 220. In this embodiment, bypass tubes 425 represent a combination of transport tubes 425a and packaging tubes 425b. Conveyor tubes 425a carry annular crown mud down between sand sieves 220 and well wall 201, while packaging tubes 425 serve as arteries to supply mud within the annular crown for packing gravel.
[00116] It is understood that the communication module and methods here are not limited by the particular design and arrangement of sand sieves 200 and bypass tubes 425, unless specifically indicated by the claims. More information regarding the use of external bypass tubes is found in U.S. Patent No. 4,945,991 and U.S. Patent No. 5,113,935. More information on internal bypass tubes is found in U.S. Patent No. 5,515,915 and U.S. Patent No. 6,227,303. [00117] The control of downhole equipment has historically been carried out through mechanical manipulation using a column of working tubes. Alternatively, the downhole equipment has been activated through the application of hydraulic pressure or through a hydraulic or electrical control line, which runs from the surface. However, it is difficult to use these traditional means when a gravel package is in position. Therefore, it is desirable to have a stand-alone tool that resides along an open-bore part or other well finishing range that can activate downhole equipment. In addition, it is desirable to employ a communication module within a well that accommodates alternative flow channels for a gravel packing operation and that can activate downhole equipment without the need for control lines and cables that run from the surface. to the sand sieves.
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31/47 [00118] Figure 5A is a perspective view of a communication module 500 according to the present invention, in one embodiment. The communication module 500 first has an internal mandrel 510. The internal mandrel 510 defines a hole 505 in it. Production fluids flow through bore 505 on the way to surface 101.
[00119] The internal chuck 510 has an internal diameter. The internal diameter is configured to generally correspond to the internal diameter of the split or perforated base tube of a sand sieve, just like any of the sand sieves 200. The internal mandrel 510 of the communication module 500 connects threadably to the base of a sand sieve joint 200. In this way, fluid communication is provided between the internal mandrel 510 and the base tube.
[00120] The communication module 500 also has an outer blanket 520. The outer cover 520 is preferably made of a metal sieving material. The screening material does not function as a filtering medium, but simply protects the components associated with the 500 communication module.
[00121] The outer cover 520 defines an inner hole 515. In the illustrative arrangement of Figure 5A, hole 515 of outer sleeve 520 is eccentric to hole 505 of inner mandrel 510. In this way, the alternative flow channels can be accommodated. In view of Figure 5A, two transport tubes 525a are seen as alternative flow channels.
[00122] Figure 5B is a cross-sectional view of the communication module 500 of Figure 5A. The view is taken through line 5B-5B of Figure 5A. In this view, the two transport tubes 525a are visible. In addition, two
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32/47 525A packaging are seen. The packaging tubes 525b receive sludge from the transport tubes 525a during a gravel packing operation and then supply the sludge within the annular crown into the well through a plurality of openings along the packaging tube 525b.
[00123] When connecting the communication module 500 with a sand control device 200, the transport tubes will be aligned. Thus, the transport tubes 525a of Figure 5A will align with the transport tubes 425a of Figure 4A for sludge supply. Naturally, it is understood that other arrangements for alternative flow channels can be employed. In this regard, the alternative flow channels can be an external bypass application (as shown in Figure 3A) or an internal bypass application (as shown in Figure 3B). [00124] The communication module 500 also has a communication line 530. In the arrangement of Figures 5A and 5B, the communication line 530 runs along and within the hole 505 of the internal mandrel 510. However, the communication line 530 can optionally be arranged external to the internal mandrel 510.
[00125] Communication line 530 may contain hydraulic fluid, such as water or a light oil. In this example, communication line 530 serves as a hydraulic control line. Alternatively, the communication line 530 may have one or more electrically conductive lines or fiber optic cables. In these examples, the communication line 530 can be considered as an electrical control line. In either embodiment, the communication line 530 operates to drive a downhole tool (not shown in Figure 5A) supplying fluid or an electrical signal as a command.
[00126] The downhole tool can be, for example, a packer. Alternatively, the downhole tool can be a sliding sleeve
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33/47 along a chuck or production pipe. Alternatively, the downhole tool may also be a valve or other inflow control device.
[00127] In order to supply fluid or a signal to the downhole tool, the communication module 500 includes a pre-programmed electrical circuit. Such a circuit is shown schematically at 540 in both Figures 5A and 5B. The pre-programmed electrical circuit 540 can be designed to send a signal that drives a hydraulic motor in response to receiving a drive signal. An illustrative hydraulic motor is seen at 550. Alternatively, the preprogrammed electrical circuit 540 can be designed to send an electrical signal (including, for example, a fiber optic light signal) in response to receiving a drive signal. In one aspect, the preprogrammed electrical circuit 540 is further programmed to send the signal after a predetermined period of time, or in response to the perception of a certain condition, such as a temperature, pressure or downhole voltage.
[00128] The communication module 500 also includes a transponder. An illustrative transponder is shown in 560. The illustrative transponder 560 is a transceiver, meaning that the device 560 incorporates both a transmitter and a receiver, which share a common circuit and enclosure. The transponder receives a signal provided through a downhole vehicle 565 and then sends its own signal to the pre-programmed electrical circuit 540.
[00129] The 565 downhole vehicle is designed to send a signal to the 560 transponder. Thus, at a designated time, the operator can drop the 565 downhole vehicle into the well and then pump it. to the bottom
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34/47 well. The downhole vehicle 565 is shown in Figure 5A moving into the internal chuck 510 in the direction indicated by the arrow “C”. The downhole vehicle 565 will finally pass through hole 505 of the communication module 500. There, the communication module 500 will be perceived wirelessly by the transmitter-receiver 560. The transmitter-receiver 560, in turn, will send a signal wired or wireless for the pre-programmed electrical circuit 540.
[00130] The 560 transponder can be tuned to send different signals in response to signals it receives from downhole carriers 565 having different frequencies. So, for example, if the operator wants to slide a glove, he can play a first 565 downhole vehicle, emitting a signal at a first frequency, which induces the 560 transponder to send a first signal to the pre electrical circuit -programmed 540 on its own first frequency, which then activates the glove through the appropriate hydraulic or electrical control. Later, the operator may wish to re-operate the glove again or place an annular packer. The operator then descends a second downhole vehicle 565 by emitting a signal at a second frequency, which induces the transmitter-receiver 560 to send a second signal to the pre-programmed electrical circuit 540 at its own second frequency, which then triggers the packer or the glove through the appropriate hydraulic or electrical control.
[00131] In a preferred embodiment, the communication module operates using radio frequency identification technology, or RFID. Figure 6 is a perspective view of a communication module 600 in an alternative embodiment, where the communication module 600 employs RFID components.
[00132] The communication module 600 of Figure 6 includes an internal mandrel 610. The
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35/47 inner mandrel 610 defines a hole 605 therein. Production fluids flow through hole 605 on the way to surface 101.
[00133] The internal mandrel 610 has an internal diameter. The internal diameter is configured to generally correspond to the internal diameter of a base tube 205 of a sand sieve, just like any of the sand sieves 200. The internal mandrel 610 of the communication module 600 is threadably connected with the base of a sand sieve joint 200. In this way, fluid communication is provided between the internal mandrel 610 and the base tube (such as the perforated base tube 205 shown in Figure 2 and Figure 4B).
[00134] The communication module 600 also has an outer cover 620. The outer cover 620 is preferably made of a metal sieving material. The screening material does not function as a filter medium, but simply protects the components within the 600 communication module.
[00135] The outer cover 620 defines an inner hole 615. The hole 615 of the outer cover 620 is substantially concentric to hole 605 of the inner mandrel 610. In this way, the alternative external flow channels can be accommodated. In the view of Figure 6A, two transport tubes 616 are partly seen as alternative flow channels.
[00136] The communication module 600 also has a communication line 630. In the illustrative arrangement of Figure 6, two communication lines 630 run along and inside the hole 615 of the outer cover 620. Thus, the communication line 630 is placed outside of the internal mandrel 610. It is understood that the communication line 630 can optionally be arranged internal to the internal mandrel 610.
[00137] Communication line 630 works in the same way as communication line 530 of Figures 5A and 5B. In this regard, communication line 630
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36/47 may contain hydraulic fluid such as water or light oil. In this example, communication line 630 serves as a hydraulic control line. Alternatively, the communication line 630 may have one or more electrically conductive lines, or fiber optic cables. In these examples, the communication line 630 can be considered as an electrical control line. In either embodiment, the communication line 630 carries a drive signal to the downhole tool by supplying fluid under pressure or by supplying an electrical command signal.
[00138] In order to supply fluid or a signal to the downhole tool, the communication module 600 includes an RFID circuit. Such a circuit is shown somewhat schematically in 640. The RFID 640 circuit can be designed to send a signal that drives a hydraulic motor in response to receiving a trigger signal. This causes the engine to pump fluid through the control line 630 under pressure. Alternatively, the RFID 640 circuit can be designed to send an electrical signal (including, for example, a fiber optic light signal) in response to receiving a trigger signal.
[00139] Communication module 600 also includes a transceiver. In this embodiment, the transponder is an RF antenna. An illustrative RF antenna 660 is a coil wound around or inside the base tube 610. The base tube 610 is made of a non-metallic material, such as ceramic or plastic, to accommodate the metal coil. The RF antenna 660 receives a signal provided through a downhole vehicle 665 and then sends its own signal to the preprogrammed RFID circuit 610.
[00140] In the RFID embodiment of Figure 6, the downhole vehicle 665 is a radio frequency tag (‘RFID’). The 665 RFID tag is designed to
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37/47 send a signal to the RF antenna 660. Generally, the RFID tag 665 consists of an integrated circuit that stores, processes and transmits the RF signal to the receiving antenna 660.
[00141] At a designated time, the operator can drop an RFID 665 tag into the well and then pump it or otherwise allow it to descend from the downhole surface. Label 665 is shown in Figure 6 moving into the internal mandrel 610 in the direction indicated by the arrow “C”. The 665 tag will finally pass through hole 605 of the communication module 600. There, the RFID 665 tag will be read wirelessly by the RF 660 antenna. The RF 660 antenna, in turn, will send a wired or wireless signal to the preprogrammed RFID circuit 640.
[00142] The communication module 600 (or RFID module) can have other components. For example, module 600 can include hydraulic motor 550 from Figure 5A. Module 600 may also include devices for reading well condition conditions, such as pressure gauges, temperature gauges, tension gauges, flow meters, in-line plot analyzers and sand detectors. The RFID 640 circuit can drive a downhole device, such as a sliding sleeve, or a packer or valve in response to readings made by such reading devices.
[00143] The communication module 600 will also have a battery (not shown). The battery provides power to the RFID circuit. The battery can also provide power to the reading equipment and any hydraulic motor.
[00144] We also observed that the information flow could be reversed. In this regard, the information perceived by the reading equipment and sent to the RFID 640 circuit can be sent to the RF antenna 660 and then transmitted
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38/47 for RFID tag 665. Tag 665 is then pumped back to surface 101 and recovered. The information received and transported by the 665 tag is downloaded and analyzed.
[00145] In yet another embodiment, the transponder that is used in a communication module is an acoustic transponder. In this arrangement, the transponder can receive acoustic signals and, when detecting a predetermined acoustic frequency, send an electrical signal.
[00146] Based on the downhole tools described above, new methods for completing an open borehole (or other) can be provided here. The methods can use the communication module described above in various embodiments to complete a well (method 700), to activate a downhole tool (method 800) or to monitor downhole conditions (method 800) (all described below), or all three.
[00147] Figure 7 provides a 700 method for completing a well. The well has a lower end defining a finishing interval. The finishing range can be a boxed hole part or an open hole part. [00148] Method 700 first includes connecting a communication module to a tubular joint. This is seen in Box 710. The communication module can sr according to any of the communication modules described above. The module will at least include alternative flow channels, configured to allow a gravel sludge to partially deviate from the communication module during a gravel packaging procedure.
[00149] The module will also have a control line. The control line is configured to reside entirely within the open bore part of the well. The control line carries a trigger command signal to a tool
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39/47 downhole inside the well.
[00150] Method 700 will also include running the communication module and the connected tubular joint into the well. This is provided in Box 720. The tubular joint may comprise a joint of a sand control device. The sand control device will have a sand sieve and alternative flow channels. Alternatively, the tubular joint can be a packer that can be placed within the finishing range before a gravel packing operation begins. Such a packer will also have alternative flow channels, so that the gravel can be packaged in the annular crown under the packer.
[00151] Method 700 also includes positioning the communication module and the tubular joint in the production part of the well. This is seen in Box 730. The production part may be a part of an open hole or a part of a boxed well that is drilled. Then, the method includes injecting a gravel slurry into an annular region formed between the communication module and the surrounding well. This is shown in Box 740. The gravel sludge also travels through at least one alternative flow channel to allow it to partially deviate from the communication module. In this way, the finishing intervals are packed with gravel under the communication module.
[00152] Preferably, the well is finished for the production of hydrocarbon fluids. Method 700 further includes producing production fluids from the finishing range. The production step is provided in Box 750. In one aspect, the finishing interval can be at least one subsurface interval of an open hole portion of the well.
[00153] In one embodiment, the control line contains an electrical line.
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40/47
In this example, method 700 may further comprise sending a command signal from the electrical circuit through the electrical line to drive the downhole tool. This is seen in Box 760. The downhole tool can be, for example, a sliding sleeve, a valve or a packer.
[00154] Method 700 operates in conjunction with the downhole vehicle. The downhole vehicle is essentially an information tag that is pumped, lowered, or otherwise released into the well. Information can flow from the downhole vehicle to the transponder, or from the transponder to the downhole vehicle. In the first aspect, the transponder is programmed to (i) receive a signal from the downhole vehicle and, (ii) in response to the received signal, send a separate instruction signal to the programmed electrical circuit to drive the tool rock bottom. In the second aspect, the transmitter receives information from the electrical circuit and sends it to the downhole vehicle. In any event, information is beneficially exchanged within the well during well operations without the need for an electrical line or a column of working tubes.
[00155] Method 700 also optionally includes placing a packer in the production part of the well. This is provided in Box 770. The packer has a sealing element to provide an annular seal between the sand control device and the surrounding formation. This makes it possible to isolate a selected range. The packer is preferably placed before the step of injecting a gravel sludge into box 740.
[00156] The communication module may also include a reading device. The reading device can be, for example, a pressure gauge, a temperature gauge, a voltage gauge, a sand detector or a flow analyzer.
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41/47 in-line plotters. The reading device is in electrical communication with the electrical circuit. In this example, method 700 also includes recording a reading by the measuring device in the electrical circuit. This is provided in Box 780.
[00157] The electrical circuit can send a signal from the electrical circuit to the control line to activate the downhole tool in response to a reading selected by the reading device. This is shown in Box 790A. Alternatively, the electrical circuit can send its signal to the transmitter, which, in turn, transmits a wireless signal, containing the recorded readings, to the downhole vehicle. This is shown in Box 790B.
[00158] A more detailed tapas progression for the Box 790B is as follows:
record a reading by the reading device in the electrical circuit, send a signal from the electrical circuit to the transponder carrying the recorded readings;
receive the signal with the readings recorded from the electrical circuit on the transmitter;
wirelessly transmit the recorded readings from the transceiver to the downhole vehicle; and supply the downhole vehicle to a surface for data analysis. [00159] A separate method for driving a downhole tool is also provided here. Figure 8 is a flowchart showing steps for a method 800 to drive a downhole tool into a well, in one embodiment. The well again has a lower end defining a finishing interval. The finishing range is preferably an open hole part.
[00160] In one embodiment, method 800 includes running a module of
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42/47 communication and a tubular joint connected into the well. This is seen in Box 810. The communication module can be according to the communication module described above. The module will at least include alternative flow channels, configured to allow a gravel sludge to deviate from the dome during a gravel packaging procedure. The module will also have a control line configured to reside entirely within the open bore part of the well. The control line carries a trigger command signal to a downhole tool within the well.
[00161] Method 800 also includes positioning the communication module and the tubular joint in the open hole part of the well. Preferably, the tubular joint is part of a sand control device. The sand control device will have a filtering screen and will also have at least one alternative flow channel. Method 800 will also include injecting a gravel slurry into an annular region formed between the sand control device and the open bore portion surrounding the well. This is seen in Box 830. The sand control device will also have at least one alternative flow channel to allow the gravel sludge to at least partially deviate from the joint of the sand control device during the gravel packing operation. .
[00162] After the communication module and the tubular joint are positioned, method 800 includes releasing a first downhole vehicle into the well. This is provided in Box 840. The downhole vehicle is essentially an information tag that is pumped, lowered or otherwise released into the well. In this arrangement, the rock bottom vehicle emits a first frequency signal. Thus, information flows from the downhole vehicle to the transponder within the well. This can occur during well operations without the need for
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43/47 an electrical line or column of working tubes extending from the surface. [00163] Method 800 also includes reading the first frequency signal on the transponder. This is shown in Box 850. In response to the first frequency signal, a first instruction signal is sent by the transponder to the electrical circuit. This is indicated in Box 860.
[00164] Method 800 also includes sending a first command signal from the electrical circuit. This is done in response to the first instruction signal and is for the purpose of driving a downhole tool. The command signal step is provided in Box 870. The actuation of the downhole tool may comprise, for example, (i) moving a sliding sleeve to close the production of a selected gap within the open hole part, (ii ) move a sliding sleeve to open the production of a selected range within the open hole part, (iii) or place a packer. The packer is preferably placed before the step of injecting a gravel sludge into Box 830.
[00165] Preferably, the communication module employs RFID technology. In such an embodiment, the pre-programmed electrical circuit is an RFID circuit. In addition, the downhole vehicle is an RFID tag that emits a radio frequency signal while the transceiver is an RF antenna.
[00166] Alternatively, the communication module employs acoustic technology. In such an example, the downhole vehicle comprises an acoustic frequency generator. The transponder then comprises an acoustic antenna that receives acoustic signals from the downhole vehicle and, in response, sends an electrical signal to the pre-programmed electrical circuit.
[00167] In one embodiment, method 800 can use a second downhole vehicle. In this example, method 800 includes releasing a second
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44/47 downhole vehicle inside the well. This is provided in Box 880. The second downhole vehicle emits a second frequency signal. The second frequency signal is read at the transponder. In response to the second frequency signal, a second instruction signal is sent from the transponder to the electrical circuit. Then, in response to the second instruction signal, a second command signal is sent by the electrical circuit to drive a downhole tool. These additional steps are seen collectively in Box 890.
[00168] With respect to method 800, it is preferred that the tubular joint, connected to the internal mandrel, be a joint of a sand control device. This joint will also have at least one alternative flow channel. Method 800 may then further include injecting a gravel slurry into an annular region formed between the sand control device and the surrounding well. During the injection process, a portion of the gravel sludge travels through at least one alternative flow channel to allow the gravel sludge to partially deviate from the joint of the sand control device. In this way, the finishing interval is packed with gravel under the communication module.
[00169] The present description finally provides a method for monitoring conditions in a well. The well again has a lower end defining a finishing interval. The finishing range is preferably a hole-open part. Monitoring takes place during hydrocarbon production operations, after a gravel packing operation has been conducted.
[00170] Figure 9 provides a flowchart showing steps for a 900 method to monitor well conditions. In one embodiment, method 900 includes
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45/47 run a communication module and a tubular joint connected inside the well. This is seen in Box 905. The communication module can be according to the communication module described above. The module will include at least alternative flow channels configured to allow the gravel sludge to partially deviate from the communication module during a packaging procedure. The module will also have a control line configured to reside entirely within the open bore part (or other finishing range) of the well. The control line carries a trigger command signal to a downhole tool within the well. In addition, the module will have an internal mandrel defining a hole through which production fluids can flow.
[00171] In support of the monitoring method 900, the communication module will also have a reading device. The reading device can read temperature, pressure, flow rate or other fluid or formation conditions. The reading device is an electrical communication with a programmed electrical circuit. The electrical circuit can record readings made by the reading device.
[00172] Method 900 also includes positioning the communication module and the tubular joint in the production part of the well. This is provided in Box 910. Preferably, the tubular joint is part of a sand control device. The sand control device will have a filtering screen and will also have at least one alternative flow channel. Method 900 will then also include placing a gravel pack along a substantial part of the production portion of the well. This is shown in Box 915.
[00173] Method 900 also includes producing hydrocarbon fluids from the well. This is seen in Box 920. Method 900 also includes reading a downhole condition. This is seen in Box 925. Reading is performed by the reading device
Petition 870190110602, of 10/30/2019, p. 50/61
46/47 during production operations. Reading occurs using a reading device that is an electrical communication with the electrical circuit.
[00174] Method 900 also includes sending readings from the reading device to the electrical circuit. This is provided in Box 930. From there, the readings are sent from the electrical circuit to a transceiver. this is provided in Box 935.
[00175] In method 900, a downhole vehicle is employed. Thus, method 900 also includes releasing a downhole vehicle into the well. This is demonstrated in Box 940. The downhole vehicle is preferably an RFID tag that emits or receives a radio frequency signal. In the example, the preprogrammed electrical circuit is an RFID circuit and the transceiver is an RF antenna.
[00176] Different means can be used to release the downhole vehicle. The downhole vehicle can be released from the surface. In this example, the operator can pump the downhole vehicle below, or it can be gravitationally sunk. Alternatively, releasing the downhole vehicle comprises releasing the downhole vehicle from a receptacle in the open-hole portion of the well at or below the communication module. This latter arrangement may include the use of a separate information tag. Thus, the method may include pumping a tag from the surface into the well, the tag emitting a first frequency signal, reading the first frequency signal on the transmitter and, in response, reading the first frequency signal, releasing the bottom vehicle from well to well.
[00177] In another example, the downhole vehicle passes through the inner mandrel or otherwise gets too close to the transmitter-receiver along the inner mandrel. The readings are then sent to the downhole vehicle.
Petition 870190110602, of 10/30/2019, p. 51/61
47/47
Thus, method 900 also includes the step of transmitting the readings from the transmitter to the downhole vehicle. This is provided in Box 945. The transmission step from Box 945 is performed wirelessly.
[00178] It is desirable to obtain readings on the surface for analysis. Since there is no electrical or optical fiber line extended from the gravel pack to the surface, the downhole vehicle must be recovered. Therefore, method 900 includes the step of recovering the downhole vehicle from the well. This is indicated in Box 950. Next, method 900 includes downloading the recorded readings for analysis. This is shown in Box 955.
[00179] Although it is evident that the inventions described here are well calculated to obtain the benefits and advantages explained above, we observe that the inventions are susceptible to modification, variation and change without deviating from their spirit. Improved methods for completing a well are provided to seal one or more selected subsurface intervals. An improved communication module is also provided. The inventions allow an operator to control a downhole tool or monitor a downhole condition.

权利要求:
Claims (20)
[1]
1. Communications module for downhole operations over a well completion interval, characterized by the fact that it comprises:
an internal mandrel;
at least one alternative flow channel along the inner mandrel, to provide a route for the gravel sludge to partially deviate from the communications module during a gravel packing operation and to enable gravel packing below the communications module:
a transponder for (i) receiving a signal and, (ii) in response to the received signal, sending a separate instruction signal;
an electrical circuit programmed to (i) receive a signal and, in response to the received signal, supply a trigger command signal; and a control line configured to reside entirely within the well completion range, the control line carrying the drive command signal provided by the electrical circuit;
where the communication module is configured to connect to a tubular joint within a well.
[2]
Communications module according to claim 1, characterized by the fact that at least one alternative flow channel comprises at least one transport tube or longitudinal bypass ring.
[3]
3. Communications module according to claim 1, characterized by the fact that the finishing interval represents an open hole part of the well.
[4]
4. Communications module according to claim 3,
Petition 870190110602, of 10/30/2019, p. 53/61
2/6 characterized by the fact that:
the communications module further comprises an external cover circumferentially arranged around the internal mandrel, the external cover allowing the flow of fluid through it; and the at least one transport tube resides (i) in a hole in the outer shell between the inner mandrel and the outer shell, or (ii) outside the outer shell.
[5]
Communications module according to claim 3, characterized in that the tubular joint comprises a joint of a sand control device.
[6]
6. Communications module according to claim 3, characterized by the fact that the tubular joint comprises a zonal insulation packer also having at least one alternative flow channel.
[7]
7. Communications module according to claim 1, characterized by the fact that the transceiver is pre-programmed to (i) receive a wireless signal emitted by a downhole vehicle and, (ii) in response to received signal, send a separate instruction signal to the electrical circuit to drive a downhole tool.
[8]
8. Communications module according to claim 7, characterized by the fact that:
the pre-programmed electrical circuit is an RFID circuit;
the downhole vehicle is an RFID tag that emits a radio frequency signal; and the transceiver is an RF antenna.
Petition 870190110602, of 10/30/2019, p. 54/61
3/6
[9]
9. Communications module according to claim 7, characterized by the fact that:
the downhole vehicle comprises an acoustic frequency generator; and the transponder comprises an acoustic antenna that receives acoustic signals from the downhole vehicle and, in response, sends the instruction signal to the electrical circuit programmed to drive the downhole tool.
[10]
10. Communications module according to claim 7, characterized by the fact that:
the control line contains a hydraulic fluid; and the communications module further comprises a hydraulic motor configured to provide pressure for the hydraulic fluid to drive the downhole tool, in response to the command signal of the preprogrammed electrical circuit.
[11]
11. Communications module according to claim 7, characterized by the fact that:
the control line contains an electrical line; and the electrical circuit is programmed to send an electrical command signal through the electrical line to drive the downhole tool.
[12]
12. Communications module according to claim 1, characterized by the fact that the communications module further comprises a reading device.
[13]
13. Communications module according to claim 12, characterized by the fact that:
Petition 870190110602, of 10/30/2019, p. 55/61
4/6 the reading device comprises a pressure gauge, a flow meter, a temperature gauge, a sand detector, a tension gauge, an in-line tracer analyzer or combinations thereof; and the reading device is in electrical communication with the electrical circuit.
[14]
14. Communications module according to claim 13, characterized by the fact that the electrical circuit is programmed to send a command signal to the control line, to activate a downhole tool in response to a reading selected by the device of reading.
[15]
15. Communications module according to claim 13, characterized by the fact that:
the electrical circuit receives and records readings from the reading device;
the electrical circuit is programmed to send a signal to the transmitter to carry the recorded readings; and the transponder is programmed to (i) receive the recorded readings from the electrical circuit and, (ii) in response to the recorded readings received, wirelessly transmit the recorded readings to a downhole vehicle.
[16]
16. Communications module according to claim 1, characterized by the fact that the downhole tool comprises a sliding sleeve, a packer, a valve or combinations thereof.
[17]
17. Method of finishing a well, the well having a lower end defining a finishing interval, characterized by the fact that it comprises:
connect a communications module to a tubular joint, the communications module comprising:
at least one alternate flow channel, configured to allow
Petition 870190110602, of 10/30/2019, p. 56/61
5/6 a gravel sludge partially deviates from the communications module during a gravel packing procedure, and a control line configured to reside entirely within the well to carry a drive command signal to a downhole tool ;
run the communications module and the tubular joint inside the well;
position the communications module and the tubular joint inside the well; and injecting a gravel sludge into an annular region formed between the communications module and the surrounding well, while providing that a portion of the gravel sludge travels through at least one alternative flow channel to allow the gravel sludge to bypass partly from the communications module and provide gravel packaging under the communication module.
[18]
18. Method according to claim 17, characterized by the fact that the communications module further comprises:
an internal mandrel; and an outer cover circumferentially disposed around the inner mandrel, the outer cover allowing fluid to flow through it.
[19]
19. Method according to claim 18, characterized by the fact that:
the tubular joint comprises a joint of a sand control device also having at least one alternative flow channel;
the internal mandrel is dimensioned to connect to a base tube of a sand control device; and injecting a gravel mud also comprises injecting the mud into
Petition 870190110602, of 10/30/2019, p. 57/61
6/6 an annular region formed between the sand control device and the surrounding well, while providing that part of the gravel sludge travels through at least one alternative flow channel, to allow the gravel sludge at least partially deviate through the joint of the sand control device.
[20]
20. Method according to claim 17, characterized by the fact that the communications module further comprises a transmitter-receiver to (i) receive a wireless signal and, (ii) in response to the received signal, send a radio signal. separate instruction; and an electrical circuit programmed to (i) receive a signal and, in response to the received signal, deliver a trigger command signal.

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同族专利:

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公开号 | 公开日

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EP2652254A4|2017-12-06|

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MX2013006303A|2013-06-28|

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CA2813999C|2017-04-11|

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CN103261576B|2016-02-24|

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EP2652254A1|2013-10-23|

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SG190677A1|2013-07-31|

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EA029620B1|2018-04-30|

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US9133705B2|2015-09-15|

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AU2011341592A1|2013-06-13|

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MX337002B|2016-02-09|

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BR112013008056A2|2016-06-14|

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US20130248172A1|2013-09-26|

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WO2012082248A1|2012-06-21|

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MY165178A|2018-02-28|

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EA201390889A1|2013-10-30|

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CA2813999A1|2012-06-21|

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AU2011341592B2|2016-05-05|

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CN103261576A|2013-08-21|

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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-08-06| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-02-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-04-07| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/11/2011, OBSERVADAS AS CONDICOES LEGAIS. |

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2021-08-24| B21F| Lapse acc. art. 78, item iv - on non-payment of the annual fees in time|Free format text: REFERENTE A 10A ANUIDADE. |

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2021-12-14| B24J| Lapse because of non-payment of annual fees (definitively: art 78 iv lpi, resolution 113/2013 art. 12)|Free format text: EM VIRTUDE DA EXTINCAO PUBLICADA NA RPI 2642 DE 24-08-2021 E CONSIDERANDO AUSENCIA DE MANIFESTACAO DENTRO DOS PRAZOS LEGAIS, INFORMO QUE CABE SER MANTIDA A EXTINCAO DA PATENTE E SEUS CERTIFICADOS, CONFORME O DISPOSTO NO ARTIGO 12, DA RESOLUCAO 113/2013. |

优先权:

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申请号 | 申请日 | 专利标题

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US42391410P| true| 2010-12-16|2010-12-16|

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PCT/US2011/058991|WO2012082248A1|2010-12-16|2011-11-02|Communications module for alternate path gravel packing, and method for completing a wellbore|

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