Apparatus and method for transporting and deploying downhole completion components

Abstract

An apparatus (50) for transporting and deploying completion components (140) for use in extended horizontal completions includes a container (52) having first and second openings (54, 56) that are substantially orthogonally disposed relative to one another. A support member (90) is securably coupled within the container (52) proximate the second opening (56). The support member (90) has a plurality of slots (92) that receive the completion components (140) in a predetermined order through the first opening (54) when the container is in a substantially horizontal position and that at least partially supports the completion components (140) when the container is in a non horizontal position such that the completion components (140) are removable through the first and second openings (54, 56) for sequential installation downhole.

Description

TECHNICAL FIELD OF THE INVENTION [0001] This invention relates, in general, to preventing the production of particulate materials from an extended horizontal wellbore traversing a hydrocarbon bearing subterranean formation and, in particular, to an apparatus and method for transporting and deploying completion components that enhance the efficiency of gravel pack completions in such wellbores. BACKGROUND OF THE INVENTION [0002] Without limiting the scope of the present invention, its background will be described in relation to gravel pack completions as an example. It is well known in the subterranean well drilling and completion art that particulate materials such as sand may be produced during the production of hydrocarbons from a well traversing an unconsolidated or loosely consolidated subterranean formation. Numerous problems may occur as a result of the production of such particulates. For example, the particulates cause abrasive wear to components within the well, such as tub...

AI Technical Summary

Benefits of technology

[0010] The present invention disclosed herein comprises an apparatus for transporting and deploying completion components such as gravel pack screens that improves the efficiency of gravel pack completions particularly in extended horizontal gravel pack completions taking place offshore. The apparatus of the present invention protects the completion components during transportation such that, for example, the need for packaging of individual gravel pack screens is eliminated and the number of required inspections of gravel pack screens is minimized. Importantly, the apparatus of the present invention reduces the likelihood of bodily injury during the deployment of the completion components on the rig site.

[0015] In operation, the completion components are loaded within the container in a predetermined sequence. A plurality of sets of spacers is positioned within the container to prevent contact between adjacent completion components during transportation which eliminates the need for packaging certain types of completion components as the spacers, the container and the support member protect the completion components from external shock and vibration as well as environmental factors. In addition, the container of the present invention allows for the completion components to be arranged within the support member in a sequence that enhances completion efficiency. Specifically, not only does the present invention increase completion efficiency by providing a container that may be positioned on or near the rig floor, but also, the present invention provides for an engineered deployment of the completion components wherein the individual completion components are deployed from the container in the order in which the completion string is assembled and installed downhole. Accordingly, as each completion component is removed from the container with the traveling block and the aid of a crane, each joint of the completion components is raised into the derrick then stabbed into the completion component that is at the top of the completion string. Importantly, the completion components may include a variety of different types of downhole components such as gravel pack screens, blank pipe, packers and the like. When the container is loaded in a predetermined sequential manner, the deployment of the completion components at the rig site is engineered such that the various completion components are deployed from the container, assembled at the rig floor and installed into the well in the desired sequence for downhole operations.

Problems solved by technology

Numerous problems may occur as a result of the production of such particulates.

For example, the particulates cause abrasive wear to components within the well, such as tubing, chokes and valves.

In addition, the particulates may partially or fully clog the well creating the need for an expensive workover.

It has been found, however, that in extended horizontal completions wherein the producing interval may be several thousand feet, it may not be feasible to perform a conventional gravel pack operation.

In these extended horizontal gravel pack completions, the process for deploying the gravel pack screens is extremely time intensive as several thousand feet of gravel pack screen may need to be installed.

It has been found, however, that this type of stacked transportation system leaves the joints of gravel pack screen susceptible to numerous perils.

For example, the system does not protect the joints of gravel pack screen from external impacts, shocks or vibrations.

Such contact may damage the gravel pack screens or cause a loss of integrity of the prepack layer within the gravel pack screens.

Due to the potential for damage during the transportation process, each joint of gravel pack screen must be inspected at least twice.

This assembly process may take as much as one hour per joint as each step in handling, unpackaging, inspecting, connecting and running the joints of gravel pack screen downhole must take place very carefully as damage to a single joint of screen may result in a loss of integrity of the gravel pack.

In addition, each step in transporting and deploying the gravel pack screens is labor-intensive requiring significant human interaction with the screens and other heavy equipment that creates opportunities for injury.

Further, a need has arisen for such an apparatus that reduces the likelihood of injury during the deployment of the gravel pack screens on the rig site.

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