CA2423771A1 - Methods and apparatus for improving performance of gravel packing systems - Google Patents
Methods and apparatus for improving performance of gravel packing systems Download PDFInfo
- Publication number
- CA2423771A1 CA2423771A1 CA002423771A CA2423771A CA2423771A1 CA 2423771 A1 CA2423771 A1 CA 2423771A1 CA 002423771 A CA002423771 A CA 002423771A CA 2423771 A CA2423771 A CA 2423771A CA 2423771 A1 CA2423771 A1 CA 2423771A1
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- Canada
- Prior art keywords
- wellbore
- perforated
- shroud
- annulus
- perforated shroud
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 50
- 238000012856 packing Methods 0.000 title claims abstract description 16
- 239000004576 sand Substances 0.000 claims abstract description 80
- 239000012530 fluid Substances 0.000 claims abstract description 44
- 238000004519 manufacturing process Methods 0.000 claims abstract description 35
- 239000011236 particulate material Substances 0.000 claims abstract description 33
- 239000000463 material Substances 0.000 claims abstract description 27
- 239000002002 slurry Substances 0.000 claims description 28
- 230000003247 decreasing effect Effects 0.000 claims description 6
- 239000004568 cement Substances 0.000 claims description 3
- 238000000151 deposition Methods 0.000 claims description 3
- 230000008774 maternal effect Effects 0.000 claims 1
- 230000005012 migration Effects 0.000 abstract description 9
- 238000013508 migration Methods 0.000 abstract description 9
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 abstract description 8
- 239000000203 mixture Substances 0.000 abstract description 6
- 229910000019 calcium carbonate Inorganic materials 0.000 abstract description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 abstract description 5
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 abstract description 4
- 239000000395 magnesium oxide Substances 0.000 abstract description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 abstract description 4
- 229910001629 magnesium chloride Inorganic materials 0.000 abstract description 2
- 230000007246 mechanism Effects 0.000 abstract description 2
- 238000002844 melting Methods 0.000 abstract description 2
- 230000008018 melting Effects 0.000 abstract description 2
- 229920000642 polymer Polymers 0.000 abstract description 2
- 239000011347 resin Substances 0.000 abstract description 2
- 229920005989 resin Polymers 0.000 abstract description 2
- 239000001993 wax Substances 0.000 abstract description 2
- 230000015572 biosynthetic process Effects 0.000 description 19
- 238000005755 formation reaction Methods 0.000 description 19
- 239000007788 liquid Substances 0.000 description 16
- 230000000903 blocking effect Effects 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 238000005086 pumping Methods 0.000 description 4
- 230000000149 penetrating effect Effects 0.000 description 3
- 230000002028 premature Effects 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 239000002360 explosive Substances 0.000 description 2
- 229930195733 hydrocarbon Natural products 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229940091250 magnesium supplement Drugs 0.000 description 2
- 230000004936 stimulating effect Effects 0.000 description 2
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 150000002680 magnesium Chemical class 0.000 description 1
- 229960002337 magnesium chloride Drugs 0.000 description 1
- 229940050906 magnesium chloride hexahydrate Drugs 0.000 description 1
- DHRRIBDTHFBPNG-UHFFFAOYSA-L magnesium dichloride hexahydrate Chemical compound O.O.O.O.O.O.[Mg+2].[Cl-].[Cl-] DHRRIBDTHFBPNG-UHFFFAOYSA-L 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/08—Screens or liners
- E21B43/086—Screens with preformed openings, e.g. slotted liners
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/04—Gravelling of wells
- E21B43/045—Crossover tools
Abstract
Improved methods and apparatus for completing well s and gravel packing an interval of a wellbore are provided. The methods include the steps of placing a perforated shroud having an internal sand screen disposed therein in the zone, and injecting particulate material into the annuli between the sand screen and the perforated shroud and the perforated shroud and the wellbore to thereby form packs of particulate material therein to prevent the migration of fines and sand with produced fluids. The perforated shroud has a flow-controlling means for restricting fluid movement between the casing/shroud and shroud/screen annuli during gravel packing. The flow-controlling means may be comprised of a material installed on a selected number of the shroud perforations which blocks or partially blocks fluid flow through the otherwise permeable wall of the perforated shroud during gravel packing. Preferably, the material is removable after the gravel has been placed, such as by melting or dissolving, to accommodate production flow during the production phase without restriction. Materials suitable for application in the improved methods include magnesium oxide/magnesium chloride/calcium carbonate mixtures, oil soluble resins, waxes, soluble polymers, etc. Other suitable materials employ other mechanisms such as temperature, oil solubility, internal breaker or flow shear stress to remove them.
Description
METHODS AND APPARATUS FOIL IMPROVING :PERFORMANCE
OF GRAVEL PACKING SYSTEMS
TECHNICAL FIELD
This invention relates to improved methods and apparatus for completing wells in unconsolidated subterranean zones, and more particularly, to improved methods and apparatus for completing such wells whereby the migration of fines and sand with the fluids produced therefrom is prevented.
BACKGROUND OF THE INVENTION
Oil and gas wells are often completed in unconsolidated formations containing loose and incompetent fines and sand which migrate with fluids producf;d by the wells. The presence of formation fines and sand in the produced fluids is disadvantageous and undesirable in that the particles abrade pumping and other producing equipment and reduce the fluid production capabilities of the producing zones in the wells.
Heretofore, unconsolidated subterranean zones have been stimulated by creating fractures in the zones and depositing particulate proppant material in the fractures to maintain them in open positions. In addition, the proppant has heretofore been consolidated within the fractures into hard permeable masses to reduce the migration of formation fines and sands through the fractures with produced fluids. Further, gravel packs which include sand screens and the like have commonly been installed in the wellbores penetrating unconsolidated zones.
The gravel packs serve as filters and help to assure that fines and sand do not migrate with produced fluids into the wellbores.
In a typical gravel pack completion, a screen is placed in the wellbore and positioned within the unconsolidated subterranean zone which is to be completed. The screen is typically connected to a tool which includes a production packer and a cross-over, and the tool is in turn connected to a work or production string. A particulate material, which is usually graded sand, often referred to in the art as gravel, is pumped in a slurry down the work or production string and through the cross over whereby it flows into the annulus between the screen and the wellbore. The liquid forming the slurry leaks off into the subterranean zone andlor through the screen which is sized to prevent the sand in the slurry from flowing therethrough. As a result, the sand is deposited in the annulus around the screen whereby it forms a gravel pack. The size of the sand in the gravel pack is selected such that it prevents formation fines and sand from flowing into the wellbore with produced fluids.
A problem which is often encountered in forming gravel packs, particularly gravel packs in long and/or deviated unconsolidated producing intervals, is the formation of sand bridges in the annulus. That is, non-uniform sand packing of the annulus between the screen and the wellbore often occurs as a result of the loss of earner liquid from the sand slurry into high permeability portions of the subterranean zone which in turn causes the formation of sand bridges in the annulus before all the sand has been placed. The sand bridges block further flow of the slurry through the annulus which leaves voids in the annulus. When the well is placed on production, the flow of produced fluids is concentrated through the voids in the gravel pack which soon causes the screen to be eroded and the migration of fines and sand with the produced fluids to result.
Incomplete packing of the interval may be caused by the liquid in the gravel slurry flowing into more permeable strata in the upper end of the formation interval and/or through the openings in the upper portion of the screen before sufficient gravel has been transported to the bottom of the completion interval.
In attempts to prevent the formation of sand bridges in gravel pack completions, special screens having internal shunt tubes have been developed and used.
While such screens have achieved varying degrees of success in avoiding sand bridges, they, along with the gravel packing procedure, are very costly.
U.S. Patent No. 4,945,991, which is incorporated herein by reference, discloses methods for gravel packing an interval of a wellbore wherein perforated shunts or conduits are provided on the external surface of the screen which are in fluid communication with the gravel slurry as it enters the annulus in the wellbore adjacent the screen.
This method does not prevent the formation of such bridges where the liquid from the slurry is lost to the upper part of the gravel pack screen.
U.S. Patent No. 5,934,376, which is incorporated herein by reference, discloses a method, basically comprising the steps of placing a slotted liner or perforated shroud with an internal sand screen disposed therein, in the zone to be completed, isolating the perforated shroud and the wellbore in the zone and injecting particulate material into the annuli between the sand screen and the perforated shroud and the wellbore to thereby form packs of particulate material therein. The system enables the fluid and sand to bypass any bridges that may form by providing multiple flowpaths via the perforated shroud/screen annulus and/or wellbore/screen annulus. See also Lafontaine, et al.: "New Con<;entric Annular Packing System Limits Bridging in Horizontal Gravel Packs," paper 56778 presented at the 1999 SPE
Annual Technical Conference and Exhibition held in Houston, Texas, Qctober 3-6, which is incorporated herein by reference.
U.S. Patent No. 5,165,476, which is incorporated herein by reference, discloses a method and apparatus for gravel packing an interval of a wellbore wherein a permeable screen having a means for restricting fluid flow from the screen-wellbore annulus into the upper portions of the screen is positioned adjacent the wellbore interval. The flow-restrictive means may be comprised of a material which remains substantially solid during circulation of the gravel slurry but preferably can be removed, e.g., by melting or dissolving, after the gravel has been placed. However, this method does not provide rr~ultiple flowpaths, or prevent the problem of premature liquid loss from the gravel slun-y to the upper end of the formation interval.
Thus, there are needs for improved methods and apparatus for completing wells in unconsolidated subterranean zones whereby the migration of formation f nes and sand with produced fluids can be economically and permanently prevented while allowing the efficient production of hydrocarbons from the unconsolidated producing zone.
SITMMARY
The present invention provides improved methods and apparatus for completing wells, and optionally simultaneously fracture stimulating the wells, in unconsolidated subterranean zones which meet the needs described above and overcome the deficiencies of the prior art.
The improved methods include the steps of placing a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between the sand screen and the perforated shroud in an unconsolidated subterranean zones and injecting particulate material into the annulus between the sand screen and the perforated shroud and into the zone by way of the perforated shroud. Fluid flow from the shroud-screen annulus out through the upper portions of the perforated shroud is restricted during the gravel placement to prevent premature liquid loss to the upper end of the formation interval.
To improve the performance of the system in reducing the potential of screenout or forming sand bridges inside the shroud-screen annulus, the number of holes or perforations on the shroud is decreased to an optimized number during the gravel packing operation.
However, the number of holes on the shroud is preferably increased during the production phase to accommodate production flov~ without restriction.
A method of preparing perforations on a shroud is included wherein, a number of perforations on the shroud is selected to be installed with screen or filter medium plate. The screen/filter plate can either be threaded or welded to the shroud so that it covers the perforations. The screen/filter is then coated or plated with a layer of dissolvable, meltable or erodable material to completely shut off the flow. After the placement of gravel in the wellbvre, the material is removed from the screen/filter, allowing perforations to open up for more flow paths during production of the well.
Materials suitable for application in the improved methods include magnesium oxide/magnesium chloridelcalcium carbonate mixtures, oil soluble resins, waxes, soluble polymers, etc. In one example, a paste form of a magnesium oxidelmagnesium chloride/calcium carbonate mixture is put on the screen/filter plates, and allowed to cure before installation of the perforated shxoud system down hole. After the gravel placement, a flush of weak HCI is applied into the wellbore and allowed to soak through the gravel pack.
The coated material on the screen/filter plates is thereby removed.
Other suitable materials employ other mechanisms such as temperature, oil solubility, internal breaker or flow shear stress to remove them from the plates. Other methods such as using ceramic discs to cover the perforations and relying on explosive charges or sonic waves to rupture or break up the discs are also applicable.
During circulation of the gravel slurry, the flow of liquid from the slurry through the upper portions of the perforated shroud is restricted so that there is little, if any, premature liquid loss through the upper portions of the perforated shroud, thereby reducing the possibility of sand bridges being formed in the annulus. .After the gravel has been deposited around the screen, fluid flow is re-established through substantially the full length of the perforated shroud.
The permeable pack of particulate material formed prevents the migration of formation fines and sand with fluids produced into the wellbore from the unconsolidated zone.
The unconsolidated formation can be fractured prior to or during the injection of the particulate material into the unconsolidated producing zone, and the particulate material can be deposited in the fractures as well as in the annuli between the sand screen and the slotted liner and between the slotted Liner and the wellbore.
The apparatus of this inventian include a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between the sand screen and the perforated shroud, a cross-over adapted to be connected to a production string attached to the perforated shroud and sand screen and a production packer attached to the cross-over. The perforated shroud has means for restricting fluid movement between the casing/shroud and shroud/screen annulus, including decreasing or increasing the number or size of holes or perforations on the shroud during gravel placement and during the production phase.
The improved methods and apparatus of this invention avoid the formation of sand bridges in the annulus between the slotted Liner and the wellbore thereby producing a very effective sand screen for preventing the migration of fines and sand with produced fluids.
It is, therefore, a general object of the present invention to provide improved methods of completing wells in unconsolidated subterranean zones.
Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of preferred embodiments which follows when taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-cross sectional view of a wellbore penetrating an unconsolidated subterranean producing zone having casing cemented therein and having a slotted Liner with an internal sand screen, a production packer and a cross-over connected to a production string disposed therein.
FIG. 2 is a side cross sectional view of the wellbore of FIG,. 1 after particulate material has been packed therein.
FIG. 3 is a side cross sectional view of the wellbore of FIG. 1 after the well has been placed on production.
FIG. 4 is a side cross sectional view of a horizontal open-hole wellbore penetrating an unconsolidated subterranean producing zone having a slotted liner with an internal sand screen, a production packer and a cross-over connected to a production string disposed therein.
FIG. S is a side cross sectional view of the horizontal open hole wellbore of FIG. 4 after particulate material has been packed therein.
FIG. 6 is a broken-away view, partly in section, showing a sample perforation on a shroud installed with a screen or filter medium plate and a soluble or removable material coated on the screen/filter plate in accordance with the present invention.
FIG. 7 is a broken-away view taken from outside the shroud, illustratively showing a sample perforation on the shroud with the blocking material installed and another perforation open to flow.
FIG. 8 is similar to FIG. 6 but showing flee blocking material installed in the perforations on the shroud directly without use of a screen/filter plate.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides improved methods and apparatus for completing, and optionally simultaneously fracture stimulating, a subterranean zone penetrated by a wellbore.
The methods can be performed in either vertical, deviated or horizontal wellbores which are open-hole and/or underreamed, or have casing cemented therein. If the method is to be carried out in a cased wellbore, the casing is perforated to provide for fluid communication with the zone. Since the present invention is applicable in horizontal and inclined wellbores, the terms "upper" and "lower," "top" and "bottom," as used herein are relative terms and are intended to apply to the respective positions within a particular wellbore, while the term "levels" is meant to refer to respective spaced positions along the wellbore.
The terms "perforated shroud" and "slotted liner" are used interchangeably throughout this invention.
Referring now to the drawings and particularly to FIGS. 1-3, a vertical wellbore 10 having casing 14 cemented therein is illustrated extending into an unconsolidated subterranean zone 12. The casing 14 is bonded within the wellbore 10 by a cement sheath 16. A plurality of spaced perforations 18 produced in the wellbore 10 utilizing conventional perforating gun apparatus extend through the casing 14 and cement sheath 16 into the unconsolidated producing zone 12.
In accordance with the methods of the present invention a perforated shroud comprised of slotted liner 20 having an internal sand screen 21 installed therein whereby an annulus 22 is formed between the sand screen 21 and the perforated shroud 20 is placed in the wellbore 10. The perforated shroud 20 and sand screen 21 have lengths such that they substantially span the length of the producing interval in the wellbore 10.
The perforated shroud is of a diameter such that when it is disposed within the wellbore 10 an annulus 23 is formed between it and the casing 14. The slots or perforations 24 in the perforated shroud can be circular as illustrated in the drawings, or they can be rectangular or other shape.
Generally, when circular slots are utilized they are at least 1/4" in diameter, and when rectangular slots are utilized they are at least 3/16" wide by 1/2°' long.
The term "screen" is used generically herein and is meant to include and cover any and all types of permeable structures commonly used by the industry in gravel pack operations which permit flow of fluids therethrough while blocking the flow of particulates (e.g., commercially-available screens, slotted or perforated liners or pipes, screened pipes, prepacked screens, expandable-type screens and/or liners, or combinations thereof). Screen 21 can be of one continuous length or it may consist of sections (e.g., 30 foot sections) connected together.
As shown in FIGS. 1-3, the perforated shroud 20 and sand screen 21 are connected to a cross-over 25 which is in turn connected to a production string 28. A
production packer 26 is attached to the cross-over 25. The cross-over 25 and production packer 26 are conventional gravel pack forming tools and are well known to those skilled in the art. The cross-over 2S is a sub-assembly which allows fluids to follow a first flow pattern whereby particulate material suspended in a slurry can be packed in the annuli between the sand screen 21 and the perforated shroud 20 and between the perforated shroud 20 and the wellbore 10.
As shown by the arrows in FIG. 2, the particulate material suspension flows from inside the production string 28 to the annulus 22 between the sand screen 21 and perforated shroud 20 by way of two or more ports 29 in the cross-over 25. Simultaneously, fluid is allowed to flow from inside the sand screen 21 upwardly through the cross-over 25 to the other side of the packer 26 outside of the production string 28 by way of one or more ports 31 in the cross-over 25. By pipe movement or other procedure, flow through the cross-over 25 can be selectively changed to a second flow pattern (shown in FIG, 3) whereby fluid from inside the sand screen 20 flows directly into the production string 28 and the ports 31 are shut off. The production packer 26 is set by pipe movement or other procedure whereby the annulus 23 is sealed.
After the perforated shroud 20 and sand screen 21 are placed in the wellbore 10, the annulus 23 between the perforated shroud 20 and the casing 14 is isolated by setting the packer 26 in the casing I4 as shown in FIG. 1. Thereafter, .as shown in FIG.
OF GRAVEL PACKING SYSTEMS
TECHNICAL FIELD
This invention relates to improved methods and apparatus for completing wells in unconsolidated subterranean zones, and more particularly, to improved methods and apparatus for completing such wells whereby the migration of fines and sand with the fluids produced therefrom is prevented.
BACKGROUND OF THE INVENTION
Oil and gas wells are often completed in unconsolidated formations containing loose and incompetent fines and sand which migrate with fluids producf;d by the wells. The presence of formation fines and sand in the produced fluids is disadvantageous and undesirable in that the particles abrade pumping and other producing equipment and reduce the fluid production capabilities of the producing zones in the wells.
Heretofore, unconsolidated subterranean zones have been stimulated by creating fractures in the zones and depositing particulate proppant material in the fractures to maintain them in open positions. In addition, the proppant has heretofore been consolidated within the fractures into hard permeable masses to reduce the migration of formation fines and sands through the fractures with produced fluids. Further, gravel packs which include sand screens and the like have commonly been installed in the wellbores penetrating unconsolidated zones.
The gravel packs serve as filters and help to assure that fines and sand do not migrate with produced fluids into the wellbores.
In a typical gravel pack completion, a screen is placed in the wellbore and positioned within the unconsolidated subterranean zone which is to be completed. The screen is typically connected to a tool which includes a production packer and a cross-over, and the tool is in turn connected to a work or production string. A particulate material, which is usually graded sand, often referred to in the art as gravel, is pumped in a slurry down the work or production string and through the cross over whereby it flows into the annulus between the screen and the wellbore. The liquid forming the slurry leaks off into the subterranean zone andlor through the screen which is sized to prevent the sand in the slurry from flowing therethrough. As a result, the sand is deposited in the annulus around the screen whereby it forms a gravel pack. The size of the sand in the gravel pack is selected such that it prevents formation fines and sand from flowing into the wellbore with produced fluids.
A problem which is often encountered in forming gravel packs, particularly gravel packs in long and/or deviated unconsolidated producing intervals, is the formation of sand bridges in the annulus. That is, non-uniform sand packing of the annulus between the screen and the wellbore often occurs as a result of the loss of earner liquid from the sand slurry into high permeability portions of the subterranean zone which in turn causes the formation of sand bridges in the annulus before all the sand has been placed. The sand bridges block further flow of the slurry through the annulus which leaves voids in the annulus. When the well is placed on production, the flow of produced fluids is concentrated through the voids in the gravel pack which soon causes the screen to be eroded and the migration of fines and sand with the produced fluids to result.
Incomplete packing of the interval may be caused by the liquid in the gravel slurry flowing into more permeable strata in the upper end of the formation interval and/or through the openings in the upper portion of the screen before sufficient gravel has been transported to the bottom of the completion interval.
In attempts to prevent the formation of sand bridges in gravel pack completions, special screens having internal shunt tubes have been developed and used.
While such screens have achieved varying degrees of success in avoiding sand bridges, they, along with the gravel packing procedure, are very costly.
U.S. Patent No. 4,945,991, which is incorporated herein by reference, discloses methods for gravel packing an interval of a wellbore wherein perforated shunts or conduits are provided on the external surface of the screen which are in fluid communication with the gravel slurry as it enters the annulus in the wellbore adjacent the screen.
This method does not prevent the formation of such bridges where the liquid from the slurry is lost to the upper part of the gravel pack screen.
U.S. Patent No. 5,934,376, which is incorporated herein by reference, discloses a method, basically comprising the steps of placing a slotted liner or perforated shroud with an internal sand screen disposed therein, in the zone to be completed, isolating the perforated shroud and the wellbore in the zone and injecting particulate material into the annuli between the sand screen and the perforated shroud and the wellbore to thereby form packs of particulate material therein. The system enables the fluid and sand to bypass any bridges that may form by providing multiple flowpaths via the perforated shroud/screen annulus and/or wellbore/screen annulus. See also Lafontaine, et al.: "New Con<;entric Annular Packing System Limits Bridging in Horizontal Gravel Packs," paper 56778 presented at the 1999 SPE
Annual Technical Conference and Exhibition held in Houston, Texas, Qctober 3-6, which is incorporated herein by reference.
U.S. Patent No. 5,165,476, which is incorporated herein by reference, discloses a method and apparatus for gravel packing an interval of a wellbore wherein a permeable screen having a means for restricting fluid flow from the screen-wellbore annulus into the upper portions of the screen is positioned adjacent the wellbore interval. The flow-restrictive means may be comprised of a material which remains substantially solid during circulation of the gravel slurry but preferably can be removed, e.g., by melting or dissolving, after the gravel has been placed. However, this method does not provide rr~ultiple flowpaths, or prevent the problem of premature liquid loss from the gravel slun-y to the upper end of the formation interval.
Thus, there are needs for improved methods and apparatus for completing wells in unconsolidated subterranean zones whereby the migration of formation f nes and sand with produced fluids can be economically and permanently prevented while allowing the efficient production of hydrocarbons from the unconsolidated producing zone.
SITMMARY
The present invention provides improved methods and apparatus for completing wells, and optionally simultaneously fracture stimulating the wells, in unconsolidated subterranean zones which meet the needs described above and overcome the deficiencies of the prior art.
The improved methods include the steps of placing a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between the sand screen and the perforated shroud in an unconsolidated subterranean zones and injecting particulate material into the annulus between the sand screen and the perforated shroud and into the zone by way of the perforated shroud. Fluid flow from the shroud-screen annulus out through the upper portions of the perforated shroud is restricted during the gravel placement to prevent premature liquid loss to the upper end of the formation interval.
To improve the performance of the system in reducing the potential of screenout or forming sand bridges inside the shroud-screen annulus, the number of holes or perforations on the shroud is decreased to an optimized number during the gravel packing operation.
However, the number of holes on the shroud is preferably increased during the production phase to accommodate production flov~ without restriction.
A method of preparing perforations on a shroud is included wherein, a number of perforations on the shroud is selected to be installed with screen or filter medium plate. The screen/filter plate can either be threaded or welded to the shroud so that it covers the perforations. The screen/filter is then coated or plated with a layer of dissolvable, meltable or erodable material to completely shut off the flow. After the placement of gravel in the wellbvre, the material is removed from the screen/filter, allowing perforations to open up for more flow paths during production of the well.
Materials suitable for application in the improved methods include magnesium oxide/magnesium chloridelcalcium carbonate mixtures, oil soluble resins, waxes, soluble polymers, etc. In one example, a paste form of a magnesium oxidelmagnesium chloride/calcium carbonate mixture is put on the screen/filter plates, and allowed to cure before installation of the perforated shxoud system down hole. After the gravel placement, a flush of weak HCI is applied into the wellbore and allowed to soak through the gravel pack.
The coated material on the screen/filter plates is thereby removed.
Other suitable materials employ other mechanisms such as temperature, oil solubility, internal breaker or flow shear stress to remove them from the plates. Other methods such as using ceramic discs to cover the perforations and relying on explosive charges or sonic waves to rupture or break up the discs are also applicable.
During circulation of the gravel slurry, the flow of liquid from the slurry through the upper portions of the perforated shroud is restricted so that there is little, if any, premature liquid loss through the upper portions of the perforated shroud, thereby reducing the possibility of sand bridges being formed in the annulus. .After the gravel has been deposited around the screen, fluid flow is re-established through substantially the full length of the perforated shroud.
The permeable pack of particulate material formed prevents the migration of formation fines and sand with fluids produced into the wellbore from the unconsolidated zone.
The unconsolidated formation can be fractured prior to or during the injection of the particulate material into the unconsolidated producing zone, and the particulate material can be deposited in the fractures as well as in the annuli between the sand screen and the slotted liner and between the slotted Liner and the wellbore.
The apparatus of this inventian include a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between the sand screen and the perforated shroud, a cross-over adapted to be connected to a production string attached to the perforated shroud and sand screen and a production packer attached to the cross-over. The perforated shroud has means for restricting fluid movement between the casing/shroud and shroud/screen annulus, including decreasing or increasing the number or size of holes or perforations on the shroud during gravel placement and during the production phase.
The improved methods and apparatus of this invention avoid the formation of sand bridges in the annulus between the slotted Liner and the wellbore thereby producing a very effective sand screen for preventing the migration of fines and sand with produced fluids.
It is, therefore, a general object of the present invention to provide improved methods of completing wells in unconsolidated subterranean zones.
Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of preferred embodiments which follows when taken in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-cross sectional view of a wellbore penetrating an unconsolidated subterranean producing zone having casing cemented therein and having a slotted Liner with an internal sand screen, a production packer and a cross-over connected to a production string disposed therein.
FIG. 2 is a side cross sectional view of the wellbore of FIG,. 1 after particulate material has been packed therein.
FIG. 3 is a side cross sectional view of the wellbore of FIG. 1 after the well has been placed on production.
FIG. 4 is a side cross sectional view of a horizontal open-hole wellbore penetrating an unconsolidated subterranean producing zone having a slotted liner with an internal sand screen, a production packer and a cross-over connected to a production string disposed therein.
FIG. S is a side cross sectional view of the horizontal open hole wellbore of FIG. 4 after particulate material has been packed therein.
FIG. 6 is a broken-away view, partly in section, showing a sample perforation on a shroud installed with a screen or filter medium plate and a soluble or removable material coated on the screen/filter plate in accordance with the present invention.
FIG. 7 is a broken-away view taken from outside the shroud, illustratively showing a sample perforation on the shroud with the blocking material installed and another perforation open to flow.
FIG. 8 is similar to FIG. 6 but showing flee blocking material installed in the perforations on the shroud directly without use of a screen/filter plate.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides improved methods and apparatus for completing, and optionally simultaneously fracture stimulating, a subterranean zone penetrated by a wellbore.
The methods can be performed in either vertical, deviated or horizontal wellbores which are open-hole and/or underreamed, or have casing cemented therein. If the method is to be carried out in a cased wellbore, the casing is perforated to provide for fluid communication with the zone. Since the present invention is applicable in horizontal and inclined wellbores, the terms "upper" and "lower," "top" and "bottom," as used herein are relative terms and are intended to apply to the respective positions within a particular wellbore, while the term "levels" is meant to refer to respective spaced positions along the wellbore.
The terms "perforated shroud" and "slotted liner" are used interchangeably throughout this invention.
Referring now to the drawings and particularly to FIGS. 1-3, a vertical wellbore 10 having casing 14 cemented therein is illustrated extending into an unconsolidated subterranean zone 12. The casing 14 is bonded within the wellbore 10 by a cement sheath 16. A plurality of spaced perforations 18 produced in the wellbore 10 utilizing conventional perforating gun apparatus extend through the casing 14 and cement sheath 16 into the unconsolidated producing zone 12.
In accordance with the methods of the present invention a perforated shroud comprised of slotted liner 20 having an internal sand screen 21 installed therein whereby an annulus 22 is formed between the sand screen 21 and the perforated shroud 20 is placed in the wellbore 10. The perforated shroud 20 and sand screen 21 have lengths such that they substantially span the length of the producing interval in the wellbore 10.
The perforated shroud is of a diameter such that when it is disposed within the wellbore 10 an annulus 23 is formed between it and the casing 14. The slots or perforations 24 in the perforated shroud can be circular as illustrated in the drawings, or they can be rectangular or other shape.
Generally, when circular slots are utilized they are at least 1/4" in diameter, and when rectangular slots are utilized they are at least 3/16" wide by 1/2°' long.
The term "screen" is used generically herein and is meant to include and cover any and all types of permeable structures commonly used by the industry in gravel pack operations which permit flow of fluids therethrough while blocking the flow of particulates (e.g., commercially-available screens, slotted or perforated liners or pipes, screened pipes, prepacked screens, expandable-type screens and/or liners, or combinations thereof). Screen 21 can be of one continuous length or it may consist of sections (e.g., 30 foot sections) connected together.
As shown in FIGS. 1-3, the perforated shroud 20 and sand screen 21 are connected to a cross-over 25 which is in turn connected to a production string 28. A
production packer 26 is attached to the cross-over 25. The cross-over 25 and production packer 26 are conventional gravel pack forming tools and are well known to those skilled in the art. The cross-over 2S is a sub-assembly which allows fluids to follow a first flow pattern whereby particulate material suspended in a slurry can be packed in the annuli between the sand screen 21 and the perforated shroud 20 and between the perforated shroud 20 and the wellbore 10.
As shown by the arrows in FIG. 2, the particulate material suspension flows from inside the production string 28 to the annulus 22 between the sand screen 21 and perforated shroud 20 by way of two or more ports 29 in the cross-over 25. Simultaneously, fluid is allowed to flow from inside the sand screen 21 upwardly through the cross-over 25 to the other side of the packer 26 outside of the production string 28 by way of one or more ports 31 in the cross-over 25. By pipe movement or other procedure, flow through the cross-over 25 can be selectively changed to a second flow pattern (shown in FIG, 3) whereby fluid from inside the sand screen 20 flows directly into the production string 28 and the ports 31 are shut off. The production packer 26 is set by pipe movement or other procedure whereby the annulus 23 is sealed.
After the perforated shroud 20 and sand screen 21 are placed in the wellbore 10, the annulus 23 between the perforated shroud 20 and the casing 14 is isolated by setting the packer 26 in the casing I4 as shown in FIG. 1. Thereafter, .as shown in FIG.
2, a slurry of particulate material 27 is injected into the annulus 22 between the sand screen 21 and the perforated shroud 20 by way of the ports 29 in the cross-over 25 and into the annulus 23 between the perforated shroud 20 and the casing 14 (or wellbore wall) by way of the slots 24 in the perforated shroud 20. The slurry can also flow directly into annulus 23 between the perforated shroud 20 and the casing 14 (or wellbore wall) after exiting the cross-over ports 31.
The particulate material flows into the perforations 18 and fills the interior of the casing 14 below the packer 26 except for the interior of the sand screen 21.
As shown in FIG. 2, a carrier liquid slurry of the particulate material 27 is pumped from the surface through the production string 28 and through the cross-over 25 into annulus 22 between the sand screen 21 and the perforated shroud 20. From the annulus 22, the slurry flows through the slots 24 and through the open end of the perforated shroud 20 into the annulus 23 and into the perforations 18. The Garner liquid in the slung leaks off through the perforations 18 into the unconsolidated zone 12 and through the screen 21 from where it flows through cross-over 25 and into the casing 14 above the packer 26 by way of the ports 31.
After the particulate material has been packed into the wellbore 10, the well is returned to production as shown in FIG. 3. The pack of particulate material 27 formed filters out and prevents the migration of formation fines and sand with fluids produced into the wellbore from the unconsolidated subterranean zone 12.
Referring now to FIGS. 4 and 5, a horizontal open-hole wellbore 30 is illustrated.
The wellbore 30 extends into an unconsolidated subterranean. zone 32 from a cased and cemented wellbore 33 which extends to the surface. As described above in connection with the wellbore 10, a perforated shroud 34 having an internal sand screen 35 disposed therein whereby an annulus 41 is formed therebetween is placed in the wellbore 30. The perforated shroud 34 and sand screen 35 are connected to a cross-over 42 which is in turn connected to a production string 40. A production packer 36 is connected to the cross-over 42 which is set within the casing 37 in the wellbore 33.
In carrying out the methods of the present invention for completing the unconsolidated subterranean zone 32 penetrated by the open-hole wellbore 30, the perforated shroud 34 with the sand screen 35 therein is placed in the wellbore 30 as shown in FIG. 4.
The annulus 39 between the perforated shroud 34 and the wellbore 30 is isolated by setting the packer 36. Thereafter, a slurry of particulate material is injected into the annulus 41 between the sand screen 35 and the perforated shroud 34, and by way of the slots 38 into the annulus 39 between the perforated shroud 34 and the wellbore 30. The slurry can also flow directly into annulus 23 between the perforated shroud 20 and the wellbore wall 30 after existing the cross-over parts 31.
The pack of particulate material 40 formed filters out and prevents the migration of formation fines and sand with fluids produced into the wellbore 30 from the subterranean zone 32.
In accordance with the present invention, perforated shroud 20 includes a means for restricting fluid movement between the casing/shroud and shroud/screen annuli by decreasing or increasing the number or size of holes or perforations on the shroud during gravel placement and during the production phase. Perforation size and number of perforations in the shroud will affect fluid movement between the casing/shroud and shroud/screen annuli.
The casing/shroud and shroud/screen annuli act as one annulus if there is an unlimited number of relatively large perforations in the shroud. A relatively small pressure differential will develop as the number of perforations and/or perforation diameter is reduced. By continuing to reduce the number of perforations and/or perforation diameter, we can control, to some extent, movement of fluid between the annuli. The slurry will continue to flow down the parallel annuli until a sand bridge or other well bore condition causes an abnormal pressure loss in one of the annuli. Once the pressure rises above that required to force flow through the perforations and the friction pressure in the annulus remaining open to flow, the slurry will reapportion itself to the annulus open to flow. As an illustration, by restricting fluid flow through the upper portions of the perforated shroud while allowing substantially unrestricted fluid flow through the lower portions thereof, no substantial amount of liquid from the gravel slurry is lost prematurely through the upper portions of the perforated shroud.
This results in the slurry continuing to the bottom of the well before the gravel is separated from the liquid in the slurry. The separated liquid flows through the lower permeable portions of the perforated shroud and/or through perforations 18 thereby depositing gravel at the bottom of the well. As the annulus of wellbore and perforated shroud and the annulus of perforated shroud and screen fills with gravel from the bottom up, the liquid in the slurry will continue to separate from the gravel and flow through the avavilable perforations 18 in the casing and/or downward through the gravel which has already been deposited in the annuli and through the lower permeable portions of the perforated shroud 20 to complete the gravel placement.
The means for restricting fluid movement between the casing/shroud and shroud/screen annuli 20 may be comprised of any material installed on a selected number of the shroud perforations which blocks or partially blocks fluid flow through the otherwise permeable wall of the perforated shroud. In the embodiment of FIG;e. 6 and 7, a selected number of the perforations 52 (only one shown, designated as 52'~ on perforated shroud 50 are installed with a screen or filter medium plate S4. The screen/filter plate 54 is threaded or welded to the shroud 50 so that it covers the desired number of perforations 52. The screen/filter 54 is then coated or plated with a layer of dissolwable, meltable or erodable material 56 to completely shut off the flow. Other materials such as ceramic plate which can be broken up afterward by explosive charges or sonic waves can also apply.
After the placement of gravel in the wellbore, the blocking material 56 is completely removed from the screen/filter 54, allowing the perforations to open up for more flow paths.
FIG. 8 shows an alternative method where blocking material 64 is installed in slots 62 of perforated shroud 60 directly without use of a screen/filter plate.
As an example of materials which can be used, a paste form of a magnesium oxide/magnesium chloride/calcium carbonate mixture can be put on the screen/filter plates, and allowed to cure before installation of the perforated shroud system down hole. After the gravel placement a flush of weak hydrochloric acid is appliedi into the wellbore and allowed to soak through the gravel pack, removing the coated material on the screen/filter plates. One specific formulation which has been developed is comprised of a mixture of 40 Pbw (Parts by weight) of calcined magnesium oxide (Mg0), 67 Pbw of MgtJl2 ' 6H20 (magnesium chloride hexahydrate), 25 Pbw of calcium carbonate (CaC03 ), and 30 Pbw of potable tap water (no brines). This material has been found to require a one day cure time at ambient temperature.
After use, it rapidly dissolves in inhibited hydrochloric acid; for example, 1-inch "plugs" of the material have completely dissolved in ten minutes at 72° h.
The methods and apparatus of this invention are particularly suitable and beneficial in forming gravel packs in long-interval horizontal wellbores without the formation of sand bridges. Because elaborate and expensive sand screens including shunts and the like are not required and the pack sand does not require consolidation by a hardenable resin composition, the methods of this invention are very economical as compared to prior art methods.
The creation of one or more fractures in the unconsolidated subterranean zone to be completed in order to stimulate the production of hydrocarbons therefrom is well known to those skilled in the art. The hydraulic fracturing process generally involves pumping a viscous liquid containing suspended particulate material into the formation or zone at a rate and pressure whereby fractures are created therein. The continued pumping of the fracturing fluid extends the fractures in the zone and carries the particulate material into the fractures.
The fractures are prevented from closing by the presence of tine particulate material therein.
The subterranean zone to be completed can be fractured prior to or during the injection of the particulate material into the zone, i.e., the pumping o:Ethe earner liquid containing the particulate material through the perforated shroud into the zone. Upon the creation of one or more fractures, the particulate material can be pumped into the fractures as well as into the perforations in the casing (for cased wells) and into the annuli between the sand screen and perforated shroud and between the perforated shroud and the wellbore.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While numerous changes may be made by those skilled in the art, such changes are included in the spirit of this invention as defined by the appended claims.
The particulate material flows into the perforations 18 and fills the interior of the casing 14 below the packer 26 except for the interior of the sand screen 21.
As shown in FIG. 2, a carrier liquid slurry of the particulate material 27 is pumped from the surface through the production string 28 and through the cross-over 25 into annulus 22 between the sand screen 21 and the perforated shroud 20. From the annulus 22, the slurry flows through the slots 24 and through the open end of the perforated shroud 20 into the annulus 23 and into the perforations 18. The Garner liquid in the slung leaks off through the perforations 18 into the unconsolidated zone 12 and through the screen 21 from where it flows through cross-over 25 and into the casing 14 above the packer 26 by way of the ports 31.
After the particulate material has been packed into the wellbore 10, the well is returned to production as shown in FIG. 3. The pack of particulate material 27 formed filters out and prevents the migration of formation fines and sand with fluids produced into the wellbore from the unconsolidated subterranean zone 12.
Referring now to FIGS. 4 and 5, a horizontal open-hole wellbore 30 is illustrated.
The wellbore 30 extends into an unconsolidated subterranean. zone 32 from a cased and cemented wellbore 33 which extends to the surface. As described above in connection with the wellbore 10, a perforated shroud 34 having an internal sand screen 35 disposed therein whereby an annulus 41 is formed therebetween is placed in the wellbore 30. The perforated shroud 34 and sand screen 35 are connected to a cross-over 42 which is in turn connected to a production string 40. A production packer 36 is connected to the cross-over 42 which is set within the casing 37 in the wellbore 33.
In carrying out the methods of the present invention for completing the unconsolidated subterranean zone 32 penetrated by the open-hole wellbore 30, the perforated shroud 34 with the sand screen 35 therein is placed in the wellbore 30 as shown in FIG. 4.
The annulus 39 between the perforated shroud 34 and the wellbore 30 is isolated by setting the packer 36. Thereafter, a slurry of particulate material is injected into the annulus 41 between the sand screen 35 and the perforated shroud 34, and by way of the slots 38 into the annulus 39 between the perforated shroud 34 and the wellbore 30. The slurry can also flow directly into annulus 23 between the perforated shroud 20 and the wellbore wall 30 after existing the cross-over parts 31.
The pack of particulate material 40 formed filters out and prevents the migration of formation fines and sand with fluids produced into the wellbore 30 from the subterranean zone 32.
In accordance with the present invention, perforated shroud 20 includes a means for restricting fluid movement between the casing/shroud and shroud/screen annuli by decreasing or increasing the number or size of holes or perforations on the shroud during gravel placement and during the production phase. Perforation size and number of perforations in the shroud will affect fluid movement between the casing/shroud and shroud/screen annuli.
The casing/shroud and shroud/screen annuli act as one annulus if there is an unlimited number of relatively large perforations in the shroud. A relatively small pressure differential will develop as the number of perforations and/or perforation diameter is reduced. By continuing to reduce the number of perforations and/or perforation diameter, we can control, to some extent, movement of fluid between the annuli. The slurry will continue to flow down the parallel annuli until a sand bridge or other well bore condition causes an abnormal pressure loss in one of the annuli. Once the pressure rises above that required to force flow through the perforations and the friction pressure in the annulus remaining open to flow, the slurry will reapportion itself to the annulus open to flow. As an illustration, by restricting fluid flow through the upper portions of the perforated shroud while allowing substantially unrestricted fluid flow through the lower portions thereof, no substantial amount of liquid from the gravel slurry is lost prematurely through the upper portions of the perforated shroud.
This results in the slurry continuing to the bottom of the well before the gravel is separated from the liquid in the slurry. The separated liquid flows through the lower permeable portions of the perforated shroud and/or through perforations 18 thereby depositing gravel at the bottom of the well. As the annulus of wellbore and perforated shroud and the annulus of perforated shroud and screen fills with gravel from the bottom up, the liquid in the slurry will continue to separate from the gravel and flow through the avavilable perforations 18 in the casing and/or downward through the gravel which has already been deposited in the annuli and through the lower permeable portions of the perforated shroud 20 to complete the gravel placement.
The means for restricting fluid movement between the casing/shroud and shroud/screen annuli 20 may be comprised of any material installed on a selected number of the shroud perforations which blocks or partially blocks fluid flow through the otherwise permeable wall of the perforated shroud. In the embodiment of FIG;e. 6 and 7, a selected number of the perforations 52 (only one shown, designated as 52'~ on perforated shroud 50 are installed with a screen or filter medium plate S4. The screen/filter plate 54 is threaded or welded to the shroud 50 so that it covers the desired number of perforations 52. The screen/filter 54 is then coated or plated with a layer of dissolwable, meltable or erodable material 56 to completely shut off the flow. Other materials such as ceramic plate which can be broken up afterward by explosive charges or sonic waves can also apply.
After the placement of gravel in the wellbore, the blocking material 56 is completely removed from the screen/filter 54, allowing the perforations to open up for more flow paths.
FIG. 8 shows an alternative method where blocking material 64 is installed in slots 62 of perforated shroud 60 directly without use of a screen/filter plate.
As an example of materials which can be used, a paste form of a magnesium oxide/magnesium chloride/calcium carbonate mixture can be put on the screen/filter plates, and allowed to cure before installation of the perforated shroud system down hole. After the gravel placement a flush of weak hydrochloric acid is appliedi into the wellbore and allowed to soak through the gravel pack, removing the coated material on the screen/filter plates. One specific formulation which has been developed is comprised of a mixture of 40 Pbw (Parts by weight) of calcined magnesium oxide (Mg0), 67 Pbw of MgtJl2 ' 6H20 (magnesium chloride hexahydrate), 25 Pbw of calcium carbonate (CaC03 ), and 30 Pbw of potable tap water (no brines). This material has been found to require a one day cure time at ambient temperature.
After use, it rapidly dissolves in inhibited hydrochloric acid; for example, 1-inch "plugs" of the material have completely dissolved in ten minutes at 72° h.
The methods and apparatus of this invention are particularly suitable and beneficial in forming gravel packs in long-interval horizontal wellbores without the formation of sand bridges. Because elaborate and expensive sand screens including shunts and the like are not required and the pack sand does not require consolidation by a hardenable resin composition, the methods of this invention are very economical as compared to prior art methods.
The creation of one or more fractures in the unconsolidated subterranean zone to be completed in order to stimulate the production of hydrocarbons therefrom is well known to those skilled in the art. The hydraulic fracturing process generally involves pumping a viscous liquid containing suspended particulate material into the formation or zone at a rate and pressure whereby fractures are created therein. The continued pumping of the fracturing fluid extends the fractures in the zone and carries the particulate material into the fractures.
The fractures are prevented from closing by the presence of tine particulate material therein.
The subterranean zone to be completed can be fractured prior to or during the injection of the particulate material into the zone, i.e., the pumping o:Ethe earner liquid containing the particulate material through the perforated shroud into the zone. Upon the creation of one or more fractures, the particulate material can be pumped into the fractures as well as into the perforations in the casing (for cased wells) and into the annuli between the sand screen and perforated shroud and between the perforated shroud and the wellbore.
Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While numerous changes may be made by those skilled in the art, such changes are included in the spirit of this invention as defined by the appended claims.
Claims (20)
1. An improved method of completing a subterranean zone penetrated by a wellbore comprising the steps of:
(a) placing in said wellbore in said zone a perforated shroud having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated shroud and a second annulus is formed between said perforated shroud and said wellbore;
(b) injecting particulate material into said second annulus between said perforated shroud and said wellbore and into said first annulus between said sand screen and said perforated shroud by way of the perforations in said perforated shroud; and (c) restricting fluid flow between said first and second annuli while said particulate material is flowing through said first and second annuli.
(a) placing in said wellbore in said zone a perforated shroud having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated shroud and a second annulus is formed between said perforated shroud and said wellbore;
(b) injecting particulate material into said second annulus between said perforated shroud and said wellbore and into said first annulus between said sand screen and said perforated shroud by way of the perforations in said perforated shroud; and (c) restricting fluid flow between said first and second annuli while said particulate material is flowing through said first and second annuli.
2. The method of claim 1 wherein said particulate maternal is sand proppant.
3. The method of claim 1 wherein said particulate material is manmade proppant.
4. The method of claim 1 wherein said wellbore in said subterranean zone is open-hole.
5. The method of claim 1 wherein said wellbore in said subterranean zone has casing cemented therein with perforations formed through the casing and cement.
6. The method of claim 1 wherein said wellbore in said zone is horizontal.
7. The method of claim 1 which further comprises the step of creating at least one fracture in said subterranean zone prior to or while carrying out the injecting step.
8. The method of claim 7 which further comprises the step of depositing particulate material in said fracture.
9. The method of claim 1 which further comprises the step of placing said subterranean zone on production.
10. The method of claim 1 wherein fluid flow between said first and second annuli is restricted in accordance with step (c) by decreasing the number of perforations on said perforated shroud.
11. The method of claim 10 wherein the number of perforations on said perforated shroud is decreased by providing a dissolvable material adjacent a selected number of said perforations.
12. The method of claim 1 which further comprises the step of increasing the flow capacity of said perforated shroud after said particulate material is packed in said first and second annuli.
13. A method for completing a subterranean zone penetrated by a wellbore comprising the steps of:
(a) placing in said wellbore in said zone a perforated shroud having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated shroud and a second annulus is formed between said perforated shroud and said wellbore;
(b) injecting particulate material into said first annulus between said sand screen and said perforated shroud and into said second annulus between said perforated shroud and said wellbore by way of the perforations in said perforated shroud; and (c) restricting fluid flow between said first and second annuli while said particulate material is flowing through said first and second annuli.
(a) placing in said wellbore in said zone a perforated shroud having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated shroud and a second annulus is formed between said perforated shroud and said wellbore;
(b) injecting particulate material into said first annulus between said sand screen and said perforated shroud and into said second annulus between said perforated shroud and said wellbore by way of the perforations in said perforated shroud; and (c) restricting fluid flow between said first and second annuli while said particulate material is flowing through said first and second annuli.
14. An apparatus for completing a subterranean zone penetrated by a wellbore comprising:
a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between said sand screen and said perforated shroud;
removable flow-controlling means along said perforated shroud to decrease fluid flow through said perforated shroud; and a crossover adapted to be attached to a workstring attached to said perforated shroud and sand screen.
a perforated shroud having an internal sand screen disposed therein whereby an annulus is formed between said sand screen and said perforated shroud;
removable flow-controlling means along said perforated shroud to decrease fluid flow through said perforated shroud; and a crossover adapted to be attached to a workstring attached to said perforated shroud and sand screen.
15. The apparatus of claim 14 wherein said flow-controlling means is comprised of a dissolvable material which is removable by flowing a fluid which will dissolve said dissolvable material along said perforated shroud.
16. The apparatus of claim 14 further comprising a production packer attached to said cross-over.
17. A method for gravel packing an interval of a wellbore, said method comprising:
positioning within the wellbore adjacent said interval a perforated liner having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated liner and a second annulus is formed between said perforated liner and said wellbore;
flowing a gravel slurry down said wellbore and into said first and second annuli and said wellbore by way of the perforations in said perforated liner; and decreasing the flow of fluid between said first and second annuli while said gravel slurry is flowing through said first and second annuli.
positioning within the wellbore adjacent said interval a perforated liner having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated liner and a second annulus is formed between said perforated liner and said wellbore;
flowing a gravel slurry down said wellbore and into said first and second annuli and said wellbore by way of the perforations in said perforated liner; and decreasing the flow of fluid between said first and second annuli while said gravel slurry is flowing through said first and second annuli.
18. A method for gravel packing an interval of a wellbore, said method comprising:
positioning within the wellbore adjacent said interval a perforated liner having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated liner and a second annulus is formed between said perforated liner and said wellbore;
flowing a gravel slurry down said wellbore and into said first and second annuli and said wellbore by way of the perforations in said perforated liner; and providing a flow-decreasing means along said perforated liner to decrease fluid flow between said first and second annuli while said gravel slurry is flowing through said first and second annuli.
positioning within the wellbore adjacent said interval a perforated liner having an internal sand screen disposed therein whereby a first annulus is formed between said sand screen and said perforated liner and a second annulus is formed between said perforated liner and said wellbore;
flowing a gravel slurry down said wellbore and into said first and second annuli and said wellbore by way of the perforations in said perforated liner; and providing a flow-decreasing means along said perforated liner to decrease fluid flow between said first and second annuli while said gravel slurry is flowing through said first and second annuli.
19. Apparatus for gravel packing an interval of a wellbore, said apparatus comprising:
a perforated liner having an internal sand screen disposed therein whereby an annulus is formed between said sand screen and said perforated liner;
flow-controlling means along said perforated liner to partially block fluid flow through said perforated liner during gravel packing when the apparatus is installed in said wellbore and to allow substantially unrestricted flow when said wellbore is placed on production.
a perforated liner having an internal sand screen disposed therein whereby an annulus is formed between said sand screen and said perforated liner;
flow-controlling means along said perforated liner to partially block fluid flow through said perforated liner during gravel packing when the apparatus is installed in said wellbore and to allow substantially unrestricted flow when said wellbore is placed on production.
20. The apparatus of claim 19 wherein said flow-controlling means comprises a layer of a removable material positioned adjacent a selected number of the perforations in said perforated liner.
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| US10/113,499 US6761218B2 (en) | 2002-04-01 | 2002-04-01 | Methods and apparatus for improving performance of gravel packing systems |
| US10/113,499 | 2002-04-01 |
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| CA2423771A1 true CA2423771A1 (en) | 2003-10-01 |
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| EP (1) | EP1350921B1 (en) |
| AU (1) | AU2003203538B8 (en) |
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| US7168489B2 (en) * | 2001-06-11 | 2007-01-30 | Halliburton Energy Services, Inc. | Orthoester compositions and methods for reducing the viscosified treatment fluids |
| US7080688B2 (en) * | 2003-08-14 | 2006-07-25 | Halliburton Energy Services, Inc. | Compositions and methods for degrading filter cake |
| US7276466B2 (en) * | 2001-06-11 | 2007-10-02 | Halliburton Energy Services, Inc. | Compositions and methods for reducing the viscosity of a fluid |
| US6830104B2 (en) | 2001-08-14 | 2004-12-14 | Halliburton Energy Services, Inc. | Well shroud and sand control screen apparatus and completion method |
| US7036587B2 (en) * | 2003-06-27 | 2006-05-02 | Halliburton Energy Services, Inc. | Methods of diverting treating fluids in subterranean zones and degradable diverting materials |
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- 2003-03-28 AU AU2003203538A patent/AU2003203538B8/en not_active Ceased
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| US20030183387A1 (en) | 2003-10-02 |
| EP1350921A2 (en) | 2003-10-08 |
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| US6761218B2 (en) | 2004-07-13 |
| EP1350921A3 (en) | 2005-03-09 |
| DE60309532D1 (en) | 2006-12-21 |
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| EEER | Examination request | ||
| FZDE | Discontinued |