Abstract:
A technique that is usable with a well includes installing a lower completion module as a unit in the well. The lower completion module includes a flow control mechanism, an annular packer, a sand screen and a flow monitoring device. Either a single unit or a plurality of the units may be installed in the well for zonal isolation and control.

Description:
BACKGROUND 
       [0001]    The invention generally relates to a downhole modular approach to a lower completion to accomplish such functions as zonal isolation, inflow, outflow, optional monitoring and/or sand management. 
         [0002]    A completed well typically includes a lower completion for purposes of communicating and controlling the production of well fluid. The lower completion may include, as an example, packers to isolate various production zones, screens to manage sand production and inflow control devices. 
         [0003]    The sand screens limit the production of particulates, or “sand.” The production of sand from the well must be controlled in order to extend the life of the well. One way to control sand production is to install screens in the well and form a substrate around the screens to filter sand from the produced well fluid. A typical sand screen is formed from a cylindrical mesh that is generally concentric with the borehole of the well where well fluid is produced. Gravel is packed in the annular region that surrounds the sand screen. The produced well fluid passes through the gravel, enters the sand screen and is communicated uphole via tubing that is connected to the sand screen. 
         [0004]    The inflow control devices regulate the rate at which well fluid flows into the lower completion. Without compensation, the flow distribution along the sand screen is non-uniform, as the pressure drop across the sand screen inherently changes along its length. An uneven well fluid flow distribution may cause various production problems. Therefore, for purposes of achieving a more uniform flow distribution, the inflow devices may be disposed along the length to modify the fluid flow distribution. The inflow control devices may also be used for purposes of shutting off production from a water producing zone, for example. 
       SUMMARY 
       [0005]    In an embodiment of the invention, a technique includes installing a lower completion module as a unit in a well. The lower completion module includes a flow control mechanism, an annular packer, and a sand screen. 
         [0006]    In another embodiment of the invention, an apparatus that is usable with a well includes a unit, which includes connectors to connect the unit to a string. The unit also includes an annular packer, a screen and a flow control mechanism. 
         [0007]    Advantages and other features of the invention will become apparent from the following drawing, description and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0008]      FIG. 1  is a schematic diagram of a lower completion module according to an embodiment of the invention. 
           [0009]      FIG. 2  is a flow diagram depicting a technique to install components in a well according to an embodiment of the invention. 
           [0010]      FIGS. 3 ,  4  and  5  are schematic diagrams of wells illustrating different configurations that may be used with the lower completion module according to embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    Referring to  FIG. 1 , an embodiment  10  of a lower completion module in accordance with the invention includes a screen  60 , which receives an incoming well fluid flow  80  from a producing zone of a well. In accordance with some embodiments of the invention, the screen  60  circumscribes an inner conduit, or base pipe  100 , of the module  10 . The screen  60 , base pipe  100  and lower completion module  10  in general are coaxial with a longitudinal axis  11 . An annular region  90 , which is created between the screen  60  and the outer surface of the base pipe  100 , receives the incoming well fluid. Unlike some conventional screens, the well fluid does not enter the base pipe  100  through openings that are circumscribed by the screen  60 . Instead, the lower completion module  10  includes a flow control mechanism  50 , which is longitudinally offset from the screen  60  and controls fluid communication between the annular region  90  and a central passageway  101  of the base pipe  100 . 
         [0012]    The flow control mechanism  50  may take on numerous forms depending on the particular embodiment of the invention. As examples, the flow control mechanism  50  may be a valve (and therefore, has a controlled, variable cross-sectional flow area) or may be an orifice that has a fixed cross-sectional flow area. The flow control mechanism  50  may be a choke, such as a fixed choke or a variable choke. As another example, the flow control mechanism  50  may be a water or a gas shut-off valve. Regardless of the particular form of the flow control mechanism  50 , the mechanism  50  controls communication between the annular region  90  that surrounds the base pipe  100  and the central passageway of the base pipe  100 . Thus, when the flow control mechanism  50  allows communication between the annular region  90  and the central passageway  101 , the incoming well flow  80  enters the screen  60  and is communicated into the annular space  90  to form an annular flow  93  along the longitudinal axis  11 . The longitudinal flow  93  passes through the flow control mechanism  50  and into the central passageway  101  of the base pipe  100  to form a flow  98  to the surface of the well. 
         [0013]    In accordance with some embodiments of the invention, the flow control mechanism  50  may be controlled by a wired or a wireless stimulus that is communicated from the surface of the well. In this regard, in accordance with some embodiments of the invention, a control line (not depicted in  FIG. 1 ) may communicate an electrical or a hydraulic signal to the flow control mechanism  50  for purposes of opening and closing the flow control mechanism  50 , varying a cross-sectional flow path of the mechanism  50 , etc. Alternatively, a wireless stimulus, such as an electromagnetic stimulus, seismic stimulus or pressure pulse (as examples) may be remotely communicated from the surface of the well or other part of the well for purposes of controlling operation of the flow control mechanism  50 . 
         [0014]    The lower completion module  10  may, in accordance with some embodiments of the invention, include an interface  41  (a sensor-based interface, for example) to detect command-encoded stimuli communicated to the module  10  for purposes of controlling the flow control mechanism  50 . In this manner, in some embodiments of the invention, the interface  41  may, in response to the command-encoded stimuli, generate the appropriate signals to control the flow control mechanism  50 . 
         [0015]    In some embodiments of the invention, the flow control mechanism  50  may employ autonomous control. In this regard, the lower completion module  10  may include an interface  40 , which senses one or more parameters of the zone in which the lower completion module  10  is located. As a more specific example, the interface  40  may be attached to sensors, such as temperature and/or pressure sensors and other devices, such as snorkel lines, for purposes of sensing a downhole condition. Thus, the lower completion module  10  may have at least one flow monitoring device to sense one or more parameters, such as a flow rate, a pressure, a temperature, a fluid composition, as few a few examples. In response to the sensed condition(s), interface  40  may generate the appropriate signals to control the flow control mechanism  50  in accordance with the sensor downhole condition(s). 
         [0016]    The flow control mechanism  50  may be controlled by performing an intervention in the well, according to some embodiments of the invention. More specifically, a service tool may be deployed into the well for purposes of the intervention. As examples, the service tool may be run into the well on a cable, tractor or pipe; may be dropped into the well (such as when the tool is a dart, ball or rod); or may be pumped down into the well. 
         [0017]    In addition to the screen  60  and the flow control mechanism  40 , in accordance with some embodiments of the invention, the lower completion  10  includes an annular packer  110 . As examples, the annular packer  110  may be an external casing packer; a bladder (such as an inflatable bladder or a metal inflatable bladder, as examples); a packer formed from a swellable material; a packer formed from an ABT hydroform material; a mechanical compression set packer; etc. Regardless of its particular form, the packer  110  may be controlled from the surface of the well; may be controlled by other downhole devices or tools; may be controlled by an electrical signal; may be hydraulically controlled; may be controlled by weight or mechanical movement of a string that is attached to the packer; and/or may be autonomously controlled for purposes of controlling the radial expansion of the packer  110  to form an annular seal in the well. For example, for a packer that contains a sealing element that is formed from a swellable material, the packer  110  expands when sufficient exposure occurs to a particular well fluid or triggering fluid. Alternatively, the radial expansion of the packer  110  may occur in response to a sensed well condition, a wired or wireless stimulus or pressure in the central passageway of the base pipe  100  (as just a few examples). Thus, many variations are possible and are within the scope of the appended claims. 
         [0018]    The lower completion module  10  includes connectors on its opposite ends for purposes of releasably connecting the lower completion module  10  to other modules, tubular members, tubular strings, etc., depending on the particular embodiment of the invention. As a more specific example, in accordance with some embodiments of the invention, the lower completion module  10  includes an upper female connector  20 , which includes an opening  22  for purposes of receiving a corresponding mating male connector. In general, the upper connector  20  may include internal bonded seals  23  for purposes for forming a sealed connection with the entity that mates with the lower completion module  10  through the connector  20 . As examples, the connector  20  may be a J-latch connector, bayonet connector or a threaded connector, depending on the particular embodiment of the invention. 
         [0019]    In accordance with some embodiments of the invention, lower completion module  10  includes a lower connector  30 , which may be a male-type connector that includes an extension  32  for purposes of forming a corresponding seal with a mating connector of a tubular string, other lower completion module  10 , etc. Depending on the particular embodiment of the invention, the lower connector  30  may be a J-latch connector, bayonet connector or a threaded connector, as just a few examples. 
         [0020]    In accordance with some embodiments of the invention, the lower completion module  10  has an integrated housing. In this context, an “integrated housing” means a housing that may be formed from one or more housing sections, which are connected together and are designed to be installed as a unit in the well. As an example, in accordance with some embodiments of the invention, the integrated housing may be formed from an upper housing  21  of the upper connector  20 ; a housing section  64  of the packer  110 ; the screen  60 ; and a lower housing  31  of the lower connector  30 . 
         [0021]    Referring to  FIG. 2 , to summarize, in accordance with some embodiments of the invention, a technique  150  includes installing a lower completion module in a well. The installation may include installing a screen, flow control mechanism and annular packer as a unit in the well, pursuant to block  152 . 
         [0022]    The flexibility of the lower completion module permits a wide range of completion configurations. For example, several screen modules  10  may be connected serially together to form a completion assembly in accordance with some embodiments of the invention.  FIG. 3  depicts a well  200  in accordance with some embodiments of the invention. The well  200  includes a tubular string  210 , which has a section of serially connected lower completion modules  10 . The string  10  extends inside a casing string  218  of the well  200  such that the lower completion modules  10  are located in various production zones of the well  200 . It is noted that although  FIG. 3  depicts the well  200  as being cased, the well  200  may be uncased in accordance with other embodiments of the invention. Additionally, the well  200  may be a subterranean or a subsea well, depending on the particular embodiment of the invention. 
         [0023]    Each particular production zone of the well  200  may be formed by one or more lower completion modules  10 . The annular packer  110  of the uppermost lower completion module  10  of the zone is set; and likewise, the bottommost lower completion module  10  of the zone may also be set to form a corresponding sealed annular region in between. For each zone, well fluid flows from the surrounding formation through the screen(s)  60  of the corresponding lower completion module(s)  10  and into the central passageway of the string  210 . 
         [0024]    It is noted that many different embodiments are possible and are within the scope of the appended claims. In this regard, the lower completion module  10  does not necessarily have to be connected to other lower completion modules  10  to fall within the scope of the appended claims. For example, referring to  FIG. 4 , in accordance with some embodiments of the invention, a well  240  may include a tubular string  242  that is connected to a single lower completion module  10 . The well  240  includes a tubular string  242 , which may extend through a casing  241  of the well  240 , although the well  240  may be cased or uncased, depending on the particular embodiment of the invention. The string  242  includes a lower completion module  10 , which is connected in line with the tubular string  242 . Below the lower completion module  10  is a packer  250  that forms a connection with the lower completion module  10 . Thus, the annular packer  110  of the lower completion module  10  and the packer  250  may be set to form a corresponding sealed annular zone for producing well fluid. 
         [0025]    As another example,  FIG. 5  depicts a well  300  in accordance with some embodiments of the invention. The well  300  includes a tubular string  310 , which extends inside a casing string  308 , although the well  300  may be cased or uncased, depending on the particular embodiment of the invention. The string  310  includes a lower completion module  10  that is connected to a conventional screen  320 . Thus, the screen  60  of the lower completion module  10  may be in use in conjunction with one or more conventional screens, which are not part of lower completion modules, as described herein. 
         [0026]    Although directional terms such as “up,” “down,” “uppermost,” etc. have been used for reasons of convenience for purposes of describing the lower completion module and its associated components and interconnections. These orientations are not necessary to practice the claimed invention. For example, the lower completion module  10  may be located in a horizontal, or lateral wellbore in accordance with other embodiments of the invention. Thus, many variations are contemplated and are within the scope of the appended claims. 
         [0027]    While the present invention has been described with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention.