BACKGROUNDWhen a hydrocarbon or other fluid is produced from a subterranean formation, the fluid typically contains particulates or sand. The production of sand from the well is typically controlled in order to extend the life of the well. Gravel packs or screens can be used to filter the particulates of the produced fluids so the fluids without the particulates can be communicated to the surface.
A challenge to using conventional gravel packing operations arises when the fluid of the gravel slurry prematurely separates from the gravel slurry, leaving the gravel behind. This is known as dehydration. When this occurs, a bridge can form in the slurry flow path, forming a bather that prevents slurry upstream of the bridge from being communicated downhole. Bridges can also disrupt and possibly prevent the packing of gravel around some parts of the sand screen, for example, leaving areas in the well devoid of gravel packing.
Another challenge associated with gravel packing operations arises when wellbore equipment, such as a packer, or another obstruction is located within the wellbore. In such cases, the gravel pack conventionally has to be diverted around these obstructions.
One way of overcoming the challenges presented during gravel packing operations is to provide alternative flow paths around obstructions, such as shunt tubes. A shunt tube can have one or more tubes called transport tubes that can deliver slurry to a number of packing tubes located along the wellbore. When a wellbore section is gravel packed, the packing tubes associated with the wellbore section can also be packed off, allowing gravel slurry flow to be diverted further down the wellbore through the transport tubes. Although the packed packing tube diverts most of the flow down the transport tube, a small amount of the gravel slurry fluid can leak through the transport tube into the packed packing tube. This leakage can cause the gravel slurry remaining in the transport tube to dehydrate and can limit the maximum length of the wellbore that can be packed.
Additionally, after one or more sections of the wellbore are gravel packed, hydrocarbons can be produced to the surface through the tubing attached to the sand screen. During production, however, the open packing tubes can allow produced fluids to enter the shunt tube system, which can have an adverse affect on the production of hydrocarbons from the wellbore.
There is a need, therefore, for new apparatus or assemblies that can selectively isolate a transport tube from a packing tube.
SUMMARYEmbodiments of the disclosure provide an exemplary packing tube isolation assembly, which includes a first conduit, a second conduit, and a sealing member. The first conduit extends substantially parallel to a longitudinal axis of a tube disposable in a wellbore and has an opening defined in the first conduit. The second conduit fluidly connects to an annulus of the wellbore and to the opening of the first conduit, and is disposed at an angle with respect to the first conduit. The sealing member is disposed adjacent the second conduit and is configured to move into and substantially obstruct the second conduit when the second conduit is at least partially packed with a gravel slurry.
Embodiments of the disclosure also provide a system for gravel packing a well, which includes a tube, first and second packing tube isolation assemblies, and a packer. The tube is at least partially disposed in the well. The first and second packing tube isolation assemblies are disposed around the tube, and each includes a first conduit, a second conduit and a sealing member. The first conduit has an opening formed through a wall thereof. The second conduit is connected to the first conduit around the opening, and is in fluid communication therewith and with the well. The sealing member is disposed adjacent the second conduit and is configured to block the second conduit when a pressure differential between the well and the first conduit reaches an activation level. Further, the packer is disposed around the tube, between the first and second packing tube isolation assemblies.
Embodiments of the disclosure further provide an exemplary method of isolating a packing tube. The exemplary method may include supplying a gravel slurry through a first conduit, and channeling at least a portion of the gravel slurry from the first conduit to a second conduit. The exemplary method may also include distributing the gravel slurry to a portion of an annulus of a wellbore through one or more outlets defined in the second conduit, and actuating a sealing member connected to the second conduit when the second conduit is at least partially packed with gravel slurry. The exemplary method may further include isolating at least a portion of the second conduit from the first conduit with the sealing member.
BRIEF DESCRIPTION OF THE DRAWINGSSo that the recited features can be understood in detail, a more particular description, briefly summarized above, may be had by reference to one or more embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 depicts a cross-sectional view of an illustrative packing tube isolation assembly in a first position, according to one or more embodiments described.
FIG. 2 depicts a cross-sectional view of the illustrative packing tube isolation assembly ofFIG. 1 in a second position, according to one or more embodiments described.
FIG. 3 depicts a schematic view of an illustrative sand completion system disposed within a wellbore and having two packing tube isolation assemblies, according to one or more embodiments described.
FIG. 4 depicts a schematic view of the illustrative sand completion system ofFIG. 3 with one of the packing tube isolation assemblies in a second position, according to one or more embodiments described.
FIG. 5 depicts a cross-sectional view of another illustrative packing tube isolation assembly in a first position, according to one or more embodiments described.
FIG. 6 depicts a cross-sectional view of the illustrative packing tube isolation assembly ofFIG. 5 in a second position, according to one or more embodiments described.
FIG. 7 depicts a cross-sectional view of yet another illustrative packing tube isolation assembly, according to one or more embodiments described.
DETAILED DESCRIPTIONFIGS. 1 and 2 depict an illustrative packingtube isolation assembly100, according to one or more embodiments.FIG. 1 shows the packingtube isolation assembly100 in first or “open” position, andFIG. 2 shows the packingtube isolation assembly100 in a second or “closed” position. In one or more embodiments, the packingtube isolation assembly100 can include a first conduit orsupply tube110 in fluid communication with one or more second conduits orslave tubes120. Thefirst conduit110 can be or include one or more tubular members or channels. For example, thefirst conduit110 can be a transport tube that can be disposed within a wellbore as part of a shunt tube system, which is shown inFIGS. 3 and4 and described below with reference thereto. Thefirst conduit110 can have one or more first flow paths115 (one shown) to transport or channel a gravel slurry therethrough.
Thesecond conduit120 can also be or include one or more tubular members or channels defining asecond flow path125 therein. For example, thesecond conduit120 can be a packing tube connected to thefirst conduit110. Thesecond conduit120 can also fluidly communicate with an annulus formed between the packingtube isolation assembly100 and a wall of a wellbore, as shown in, and described below with reference to,FIGS. 3 and 4.
Thefirst flow path115 can be in selective fluid communication with thesecond conduit120. For example, thefirst conduit110 can have one ormore openings112 formed therethrough, allowing the first andsecond conduits110 and120 to fluidly communicate. As used herein, the term “selective fluid communication” is generally defined to mean that a flow can be allowed or partially or completely blocked, obstructed, or otherwise attenuated as desired.
In one or more embodiments, thesecond conduit120 can have afirst portion122 and asecond portion124 that can be welded, riveted, or otherwise fastened or affixed to thefirst conduit110 around theopening112. Thefirst portion122 can be disposed at an angle relative to a longitudinal axis of thefirst conduit110, such that thefirst portion122 of thesecond conduit120 is not parallel to thefirst conduit110, and at least a portion of thesecond portion124 can be substantially parallel to the longitudinal axis of thefirst conduit110. The angle of thefirst portion122 can be, for example, any angle greater than 0 degrees, and can range from about 0.5 degrees to about 90 degrees, from about 20 degrees to about 70 degrees, or from about 30 degrees to about 60 degrees. The first andsecond portions122 and124 can be provided by a single tubular member that is, for example, bent, or can be two discrete tubular members fixed together at the desired angle, by welding or fastening, for example, using flanges, or the like.
One or more ports or outlets (three are shown128A,128B, and128C) can be formed through thesecond portion124 of thesecond conduit120. Theoutlets128A,128B,128C allow fluid communication between thefirst flow path115 of thefirst conduit110 through thesecond conduit120 to an area external to the packingtube isolation assembly100, as described below with reference toFIGS. 3 and 4. Although not shown, theoutlets128A,128B,128C can include one or more nozzles connected to or disposed within thesecond conduit120.
Thesecond conduit120 can further include one ormore chambers140 disposed therein. Thechamber140 can be disposed within thesecond conduit120, adjacent thefirst portion122. Thechamber140 can be in fluid communication with thefirst flow path115 and thefirst conduit110 via a flow path orinlet160. Thechamber140 can also be in fluid communication with the exterior of the packingtube isolation assembly100, such as theannulus148 of a wellbore, via a flow path oroutlet170, as shown in and described below with reference toFIGS. 3 and 4. Theflow paths160,170 can be an aperture, channel, conduit, control line, or the like.
In one or more embodiments, aflow control device165 can be located in theinlet160 to allow selective communication between thechamber140 and thefirst conduit110. Illustrativeflow control devices165 can include rupture disks, pressure relief valves, or any other pressure sensitive devices. In another exemplary embodiment, theflow control device165 can be a dissolvable plug or a solenoid. In another example, theflow control device165 can be a pressure-sensitive device that is selectively actuatable or opened by exposure to an activation level of pressure differential or another trigger, as described below.
A sealingmember150 can be at least partially disposed within thechamber140. The sealingmember150 can be any slidable body or member that can move from a first or “open” position within thechamber140, as depicted inFIG. 1, to a second or “closed” position within thechamber140, as depicted inFIG. 2. When the sealingmember150 is in the first or “open” position (FIG. 1), thefirst flow path115 can be in fluid communication with thesecond flow path125. When the sealingmember150 is in the second or “closed” position (FIG. 2), thefirst flow path115 can be prevented from communicating with thesecond flow path125.
In at least one specific embodiment, the sealingmember150 can act as a piston that is moveable by applying a force against an upper surface thereof. As depicted inFIG. 1, the sealingmember150 can be substantially flat at an upper surface or first end thereof, and can be tapered or frustoconical at a second end thereof to correspond to the angledfirst portion122 of thesecond conduit120, among many other equally effective configurations are envisaged. As such, the sealingmember150 acts as a gate or switch to allow or block fluid flow through theopening112, between thefirst flow path115 and thesecond flow path125.
In at least one specific embodiment, the sealingmember150 can be actuated by pressure within thefirst conduit110. For example, when thesecond conduit120 is packed or blocked, a pressure differential can form within thefirst conduit110. The pressure within thefirst conduit110 can rupture or otherwise cause theflow control device165 to open, thereby placing theflow control device165 in an open configuration. When theflow control device165 is in an open configuration, pressure within thefirst conduit110 can be communicated to thechamber140, via thefirst inlet160. When the sealingmember150 is axially moved, at least a portion of the sealingmember150 can extend past thechamber140 and block theopening112 to thesecond conduit120. Accordingly, communication betweenflow paths115,125 can be blocked or prevented.
Theoutlet170 can allow fluids such as air or liquids entrained within thechamber140 to escape, i.e. vent, into theannulus148 of the wellbore or theflow path125 when the sealingmember150 moves from the first position to the second position. Such communication can avoid or minimize back pressure that might otherwise impede the progression of the sealingmember150 from the first position to the second position.
In one or more embodiments, the sealingmember150 can be restrained in the first position by a restrainingelement151.Illustrative restraining elements151 can include shear pins or shear screws.Illustrative restraining elements151 can also include an electrically-actuating element, such as solenoid, or a pneumatically- or hydraulically-actuating element, or the like. In operation, the restrainingelement151 can receive a signal to be released, thereby releasing the sealingmember150 from its first position to the second position (FIG. 2). One or more control lines can be used to transmit a release signal to the restrainingelement151. Illustrative control lines can include hydraulic control lines, pneumatic control lines, electronic control lines, or similar control lines. In one or more embodiments, wireless telemetry can be employed instead of, or in addition to, control lines.
FIG. 3 depicts an exemplary embodiment of asand completion system300, which integrates a plurality of the packingtube isolation assemblies100, for example, a firstpacking tube assembly100A and a secondpacking tube assembly100B. It will be appreciated that various embodiments of thesand completion system300 can include additional or fewer packingtube isolation assemblies100, and may also include other packing tube isolation devices. Thesand completion system300 can be disposed in awellbore340, and can include one or more particulate control devices, for example, first and secondparticulate control devices352,354, and atube305. Thefirst conduits110 of the packingtube isolation assemblies100A, B can be disposed substantially parallel to a longitudinal axis of thetube305, such that, for example, in a vertical portion of thewellbore340, thefirst conduits110 are also vertically oriented. One or more packer assemblies (three are shown:370,380,385) can be located around thecompletion system300.
In one or more embodiments, the first and secondparticulate control devices352,354 can be sand control screens. For example, the first and secondparticulate control devices352,354 can be commercially-available screens, slotted or perforated liners or pipes, screened pipes, pre-packed or dual pre-packed screens and/or liners, or combinations thereof. Thepacker assemblies370,380,385 can include one or more sealing members. For example thepacker assemblies370,380,385 can include one or more packers capable of sealing off the annular region orannulus364 between thecompletion system300 and thewellbore340.Illustrative packer assemblies370,380,385 can include compression or cup packers, inflatable packers, swellable packers, “control-line bypass” packers, polished bore retrievable packers, other common downhole packers, or combinations thereof.
In exemplary operation, thecompletion system300 can be conveyed into thewellbore340, and can be used to perform downhole operations such as gravel packing. Thewellbore340 can have an open or cased borehole. When thewellbore340 has a cased borehole, thewellbore340 can have acasing343. Thewellbore340 can have one or more hydrocarbon producing zones, for example, first and secondhydrocarbon producing zones342,348.
Thecompletion system300 can be located within thewellbore340, such that, in an exemplary embodiment, at least one packingtube isolation assembly100 can be associated or placed adjacent each of potentially many identified hydrocarbon producing zones. For example, the first packingtube isolation assembly100A can be located adjacent the firsthydrocarbon producing zone342, and the second packingtube isolation assembly100B can be located adjacent the secondhydrocarbon producing zone348.
After locating thecompletion300 within thewellbore340, thepacker assemblies370,380,385 can be set. Thepacker assemblies370,380,385 can define first andsecond wellbore regions366,368, by isolating the first and secondhydrocarbon producing zones342,348 from one another. Thepacker assemblies370,380,385 can be set by application of pressure, by application of axial force through thetube305, by swelling, or in other ways known in the art.
In an exemplary embodiment, thepacker assemblies370,380 can isolate the firsthydrocarbon producing zone342 and define thefirst wellbore region366. Thepacker assemblies380,385 can similarly isolate the secondhydrocarbon producing zone348 and define thesecond wellbore region368. Consequently, thefirst wellbore region366 can be associated with the firsthydrocarbon producing zone342, and thesecond wellbore region368 can be associated with the secondhydrocarbon producing zone348.
The first packingtube isolation assembly100A can be deployed to thefirst wellbore region366, and the second packingtube isolation assembly100B can be deployed to thesecond wellbore region368. Theparticulate control device352 can be also be deployed to thefirst wellbore region366, and theparticulate control device354 can likewise be deployed to thesecond wellbore region368. In one or more embodiments, thefirst conduit110 of the first packingtube isolation assembly100A can be configured to extend through thepacker assemblies370,380 and can connect with thefirst conduit110 of the second packingtube isolation assembly100B. As such, thefirst conduits110 of the adjacent packingtube isolation assemblies100A, B can be in fluid communication with one another. Further, thepacker assemblies380,385 can seal about the exterior of the portion of thefirst conduit110 extending therethrough.
In an exemplary embodiment, after thepacker assemblies370,380,385 are set,gravel slurry390 can be pumped or sent down thefirst conduit110 of the first packingtube isolation assembly100A. Thegravel slurry390 can flow from the first flow path115 (FIGS. 1 and 2) of the first packingtube isolation assembly100A through thesecond conduit120 to thesecond flow path125. Thegravel slurry390 can flow along thesecond flow path125 tooutlet128, which can beoutlets128A,128B,128C (FIGS. 1-2), of thesecond conduit120. Thegravel slurry390 can flow through theoutlet128 into theannular region364 of thefirst wellbore region366. Thegravel slurry390 can pack about the firstparticulate control device352 as the fluid in thegravel slurry390 migrates through theparticulate control device352. The fluid of thegravel slurry390 that migrates through theparticulate control device352 can return to the surface, via thetube305.
Thegravel slurry390 can be supplied to theannular region364 of thefirst wellbore region366, until thegravel slurry390 at least partially covers or packs theoutlet128 and/or thesecond conduit120 of the first packingtube isolation assembly100A. A pressure differential can be created between thefirst conduit110 of the first packertube isolation assembly100A and thefirst wellbore region366 when at least some of the outlets128 (e.g.,128A,128B,128C ofFIGS. 1-2) and/or thesecond conduit120 are at least partially packed withgravel slurry390.
With additional reference toFIGS. 1 and 2, in an exemplary embodiment, theflow control device165 can be configured to rupture, open a pressure relief valve, shear frangible pins or screws, and/or otherwise communicate thechamber140 with thefirst conduit110 in response to the described pressure differential. For example, a desired activation level of the pressure differential can be predetermined, and theflow control device165 can be configured to allow communication through theinlet160 in response thereto. In an exemplary embodiment, theflow control device165 can rupture, allowing agravel slurry390, and/or other fluid within thefirst conduit110 to communicate with aspace145 in thechamber140, viainlet160, thereby applying the pressure differential across the sealingmember150. In another exemplary embodiment, after the pressure differential is recorded, for example, with a pressure transducer (not shown), a user or computer at the surface can transmit a control signal to theflow control device165 via control lines or wireless telemetry. This can prompt theflow control device165 to move into an open position, which can allow the communication of fluid therethrough and/or to release the sealingmember150 from the first position, if the sealingmember150 has been restrained therein.
The ingress ofgravel slurry390 or other fluids from thefirst conduit110 into thespace145 can be propelled by the pressure differential between thefirst conduit110 and the packedfirst wellbore region366. The ingress of thegravel slurry390 can urge, propel, actuate, and/or slide the sealingmember150 from the first position to the second position as thegravel slurry390 enters thechamber140. In an exemplary embodiment, the sealingmember150 can also, or instead, be urged manually from the first position to the second position using a mechanical device (not shown). The sealingmember150 in the second position can block thesecond conduit120 and isolating theflow paths115,125 from one another, as shown inFIG. 2. The isolation of the first andsecond flow paths115,125 of the first packingtube isolation assembly100A from one another, can effectively prevent undesired fluid loss of thegravel slurry390 through theflow path125 as lower wellbore regions are gravel packed, and can prevent hydrocarbons produced inwellbore region366 from entering thefirst conduit110 of the first packingtube isolation assembly100A.
After the sealingmember150 of the first packingtube isolation assembly100A is actuated, thegravel slurry390 can flow to lower wellbore regions, such as thesecond wellbore region368, as shown inFIG. 4.FIG. 4, with continuing reference toFIG. 3, depicts thesand completion system300, with thefirst wellbore region366 having been gravel packed as described above, and the sealingmember150 effectively isolating the first andsecond flow paths115,125 of the first packingtube isolation assembly100A from one another. Consequently, the flow ofgravel slurry390 can bypass thefirst wellbore region366 and can flow to thefirst flow path115 of the second packingtube isolation assembly100B. Thegravel slurry390 can flow from theflow path115 of the second packingtube isolation assembly100B to theflow path125 of the second packingtube isolation assembly100B. Once thegravel slurry390 gravel packs anannulus365 of thesecond wellbore region368, the sealingmember150 of the second packingtube isolation assembly100B can block the continued flow ofgravel slurry390, in a similar operation as that just described with reference to the first packingtube isolation assembly100A.
Gravel packing, as described for the first andsecond wellbore regions366,368, can be repeated for any additional wellbore regions of thewellbore340. When gravel pack operations of one or more wellbore regions of thewellbore340 are completed, production operations can be conducted. During production operations, hydrocarbons produced from each of thehydrocarbon producing zones342,348 (and any others) can be communicated to the surface, via thetube305. In one or more embodiments, thecompletion system300 can be adapted to allow for selective simultaneous production of hydrocarbons from eachhydrocarbon producing zone342,348 or hydrocarbons can be independently produced from one or more of thehydrocarbon producing zones342,348. For example, flow control devices (not shown) can be disposed about thetube305 and can be selectively actuated to control the flow of hydrocarbons into thetube305.
FIGS. 5 and 6 depict another embodiment of the packingtube isolation assembly100. The packingtube isolation assembly100 can be substantially similar to those described above with reference to, and shown in,FIGS. 1 and 2, and can include a flapper orreed200 connected to or adjacent thechamber140, such that theflapper200 pivots from a first flapper position to a second flapper position. When theflapper200 is in the first flapper position, theflapper200 can be generally parallel to, and, in one or more embodiments, flush with thefirst portion122 of thesecond conduit120. In this position, theflapper200 can cover at least a portion of the sealingmember150, thereby opposing the sealingmember150 moving out of the first or “open” position.
When the activation level of pressure differential is present or it is otherwise desired to move the sealingmember150 to the second position, as described above with reference toFIGS. 1 and 2, the sealingmember150 can push theflapper200 into the second flapper position, as shown inFIG. 6. When theflapper200 is in the second flapper position, theflapper200 can extend at least partially through thefirst portion122 of thesecond conduit120, thereby allowing the sealingmember150 to, for example, descend partially out of thechamber140 into thesecond conduit120. In one or more embodiments, theflapper200 can have a small cross-section relative to a cross-section of thefirst portion122. Accordingly, even when theflapper200 is in the second flapper position, it can allow relatively free fluid communication between thesecond conduit120 and thefirst conduit110.
In one or more embodiments, theflapper200 can be elastically deformed by the movement of the sealingmember150 to second position, such that theflapper200 essentially fails and releases the sealingmember150. In one or more embodiments, theflapper200 can be hinged and restrained in the first flapper position by any suitable device, such as a pin, solenoid and/or the like, and then released such that movement of the sealingmember150 to the second position releases theflapper200.
In one or more embodiments, the sealingmember150 can be urged from the first position (FIG. 5) to the second position (FIG. 6) using a biasingmember202, which can be or include a spring or the like. In one or more embodiments, the biasingmember202 can be or include a leaf spring, compression spring, or any resilient member. The biasingmember202 can be restrained in a compressed state when the sealingmember150 is in the first position. The biasingmember202 can thus supply a force to aid the movement of the sealingmember150 to the second position.
FIG. 7 depicts yet another illustrative packingtube isolation assembly100, which can be substantially similar to any of the illustrative packingtube isolation assemblies100 described above. In one or more embodiments, the packingtube isolation assembly100 can include amagnetic actuator250. Themagnetic actuator250 can be a passive fixed-pole magnet, such that themagnetic actuator250 can supply a generally constant magnetic field to attract the sealingmember150, thereby aiding in drawing the sealingmember150 from the first position to the second position. In one or more embodiments, themagnetic actuator250 can instead apply a repulsive force on the sealingmember150 to maintain the sealingmember150 in the first position. In one or more embodiments, themagnetic actuator250 can additionally include or instead be an electromagnet which may be remotely-controlled via wired connections or wireless telemetry, for example, such that themagnetic actuator250 can provide a magnetic field of selectable strength and direction to attract or repel the sealingmember150. Furthermore, themagnetic actuator250 can be a solenoid that connects to the sealingmember150, or can be a disk or block magnet or the like.
Accordingly, in one or more embodiments, the amount of force required to move the sealingmember150 from the first position to the second position can be balanced between any combination of components that resist and those that assist the movement of the sealingmember150 from the first position to the second position. For example, the resistance of any combination of the restraining member151 (FIG. 1), flapper200 (FIG. 5), and/or the magnetic actuator250 (FIG. 7), can be balanced with the urging of the biasing member202 (FIG. 6), the magnetic actuator250 (FIG. 7), and/or the pressure differential described above, until the force is sufficient to move the sealingmember150 to the second position.
As used herein, the terms “up” and “down”; “upper” and “lower”; “upwardly” and “downwardly”; “upstream” and “downstream”; and other like terms are merely used for convenience to describe spatial orientations or spatial relationships relative to one another in a vertical borehole. However, when applied to equipment and methods for use in deviated or horizontal boreholes, it is understood to those of ordinary skill in the art that such terms are intended to refer to a left to right, right to left, or other spatial relationship as appropriate.
Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.