Multi-zone Single Trip Completion System with Circulation Tubes
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Solution Overview
Problem
Conventional wellbore completion systems require multiple trips and the use of service tools for multi-zone treatments, leading to increased risks, costs, and inefficiencies, particularly in maintaining zonal isolation and reversing out excess fluids during dehydration processes.
Innovation Solution
A multi-zone completion system with a circulation system comprising circulation tubes and valves, allowing for various fluid flow paths and pressure transmissions without the need for service tools, enabling single-trip operations for gravel packing, acid stimulation, fracturing, and slurry dehydration while maintaining zonal isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-zone completion systems are used, then multiple trips and service tools are required for installing completion tools and performing operations, but this increases risk, time, and cost
Solution Approach 1:
The patent combines multiple completion operations (gravel packing, frac packing, acid stimulation, fracturing) that traditionally required separate trips into a single integrated operation. The multi-zone completion system allows all these treatments to be performed in one trip by integrating the necessary tools and functions into a unified system that can handle multiple zones simultaneously.
Solution Approach 2:
The completion system is designed with multi-functional capabilities to perform various completion operations without requiring service tools. The system includes integrated components that can execute gravel packing, frac packing, acid stimulation, and fracturing operations across multiple zones, eliminating the need for additional service tool trips.
2Adaptability or versatility
If conventional systems treat approximately five zones in one trip, then some zones can be treated, but most wells with far greater than five zones still require multiple trips
Solution Approach 1:
The completion system is divided into multiple independently controllable zones, each with its own treatment capabilities. This segmentation allows the system to handle a large number of zones (far exceeding five) by treating each zone independently through dedicated ports and control mechanisms, while still operating within a single trip.
Solution Approach 2:
The system transitions from treating a limited number of zones sequentially to handling multiple zones simultaneously through parallel processing capabilities. By adding the dimension of concurrent multi-zone treatment, the system can accommodate wells with far greater than five zones without requiring additional trips.
3Reliability
If service tools are used to selectively control which zone is treated, then zonal isolation can be maintained, but moving the service tool around while particulate laden fluids are present causes the tool to become stuck
Solution Approach 1:
The service tool is extracted from the system and replaced with a completion system that maintains zonal isolation through integrated mechanical means. The system uses packers, isolation valves, and sealed ports built into the completion architecture itself, eliminating the need for a separate service tool that would need to move through particulate-laden fluids.
Solution Approach 2:
The completion system is designed to maintain zonal isolation and control fluid flow automatically through its built-in mechanical components. The system self-regulates zone isolation through packers and isolation mechanisms that do not require external service tool intervention, allowing operations to proceed without moving tools through problematic fluid environments.
4Adaptability or versatility
If service tools are moved into various positions by moving the work string from surface, then zone selection is possible, but each service tool trip takes hours to complete and is excessively time consuming
Solution Approach 1:
Zone selection and isolation mechanisms are established in advance during the initial completion installation. The system pre-configures packers, isolation valves, and controlled ports for each zone before production begins, eliminating the need for time-consuming service tool trips to reposition and select zones during operation.
Solution Approach 2:
The mechanical service tool positioning system is replaced with a more efficient control mechanism. The system uses pre-installed isolation packers and controlled ports that can be activated or deactivated without physical repositioning, substituting the slow mechanical movement of service tools with faster activation of pre-positioned components.
5Ease of manufacture
If conventional systems require additional screens for dehydration and cannot take returns through production screens, then dehydration can be performed, but the system cannot maintain zonal isolation during dehydration processes
Solution Approach 1:
The system introduces circulation tubes as intermediary pathways that allow fluid to bypass the production screens during dehydration operations. These dedicated circulation paths enable dehydration fluids to flow through isolated channels that do not compromise the integrity of production screens or zonal isolation, mediating between dehydration requirements and production integrity.
6Device complexity
If simple check valves are used for production ports, then the system is simpler, but they do not stop pressure two ways
Solution Approach 1:
The valve system transitions from static simple check valves to dynamic valves that can actively respond to pressure conditions. The system uses valves capable of bidirectional pressure containment that can automatically adjust their sealing characteristics based on flow direction and pressure differentials, providing reliable two-way pressure stopping while maintaining operational simplicity.
Data Source
AI summary
A multi-zone, one trip completion system for a wellbore is described. A plurality of isolation packers is installed in borehole to isolate a plurality of zones of the annulus between a tubing string and a wellbore. Each tubing string section is positioned in a zone and comprises a selectively openable stimulation port to provide stimulation fluid to its zone and a selectively openable production port to receive fluid from its zone. The system also comprises a circulation system with a plurality of circulation tubes and circulation tube valves, being configurable in a plurality of configurations to selectively connect, via a circulation flow path, the central bore or the borehole annulus of a wellbore at each of the plurality of sections, to an upper circulation flow path open to an annulus above an uppermost of the plurality of isolation packers.