Completion systems with a bi-directional telemetry system

An apparatus for use in a wellbore for performing a treatment operation is disclosed that in one non-limiting embodiment may include an inner string that further includes a first tubular having a first communication link, and a service tool including a cross-over tool having a fluid flow passage therein for supplying a treatment fluid under pressure from an inside of the service tool to an outside of the service tool, and wherein the service tool includes a second communication link operatively coupled to the first communication link and wherein the second communication link runs across or through the fluid flow passage in the cross-over tool that is protected from direct flow of the fluid under pressure from the inside of the service tool to the outside of the service tool.

BACKGROUND

1. Field of the Disclosure

This disclosure relates generally to apparatus and methods for completing a wellbore for the production of hydrocarbons from subsurface formations, including fracturing, gravel packing and flooding selected zones and for communicating information in real-time about various downhole operations.

2. Background of the Art

Wellbores are drilled in subsurface formations for the production of hydrocarbons (oil and gas). Modern wells can extend to great well depths, often more than 6000 meters (about 20,000 ft.). Hydrocarbons are trapped in various traps in the subsurface formations at different depths. Such sections of the formation are referred to as reservoirs or hydrocarbon-bearing formations or zones. Some formations have high mobility, a measure of the ease of the hydrocarbons flow from the reservoir into a well drilled through the reservoir under natural downhole pressures. Other formations possess low mobility and the hydrocarbons trapped therein are unable to move with ease from the reservoir into the well. Stimulation methods are typically employed to improve the mobility of the hydrocarbons through the reservoirs. One such method, referred to as fracturing (also referred to as “fracing” or “fracking”), is often utilized to create cracks in the reservoir to enable the fluid from the formation (formation fluid) to flow from the reservoir into the wellbore. To sand control, frac-pacing and gravel packing multiple zones, an assembly containing an outer string with an inner string therein is run in or deployed in the wellbore. The outer string is conveyed in the wellbore with a tubing attached to its upper end and it includes various devices corresponding to each zone to be fractured for supplying a fluid with proppant to each such zone. The inner string (also referred to as the “service string”) includes devices or tools attached to a tubing (which tubing can extend over 1,000 meters (about 3,000 feet) to perform a number of operations during treatment or service operations, including, but not limited to, setting an upper packer with a packer setting tool, setting a tool at selected locations of the outer string, setting packers, opening and closing valves, flowing fracture fluid from the inner string into the production zones via a frac port, and performing reverse flow and return flow operations. In such systems, It is desirable to obtain real-time information about the various operations performed in a wellbore using the inner string and outer string, including determining location of a device or element downhole, setting a device, fluid flow, temperature and pressure profiles, quality of the performed operations, etc. from various location along the inner string, including locations below the frac port. However, commercially utilized inner strings that include a packer setting tool and frac port are not available with a control line or communication link that runs from the surface to a location below the frac.

The disclosure herein provides systems and methods for use in wellbore operations that include a two-way communication system for providing real-time information between a surface location and downhole devices and operations, including information from locations below the frac port.

SUMMARY

In one aspect, an apparatus for use in a wellbore for performing a treatment operation is disclosed that in one non-limiting embodiment may include an inner string that further includes a first tubular having a first communication link, and a service tool including a cross-over tool having a fluid flow passage therein for supplying a treatment fluid under pressure from an inside of the service tool to an outside of the service tool, and wherein the service tool includes a second communication link operatively coupled to the first communication link and wherein the second communication link runs across or through a through passage in the cross-over tool that is protected from direct flow of the fluid under pressure from the inside of the service tool to the outside of the service tool.

In another aspect, a method of performing a treatment operation in a wellbore is disclosed that in one non-limiting embodiment may include: providing an outer string; providing an inner string for placement inside the outer string, wherein the inner string includes a cross-over tool for supplying fluid under pressure from the inner string to the outer string; and running a communication link across or through the crossover tool that is protected from direct flow of the fluid from the inner string to the outer string through the cross-over tool.

Examples of the more important features of a well treatment system and methods that have been summarized rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features that will be described hereinafter and which will form the subject of the claims.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1is a line diagram of a section of an exemplary multi-zone wellbore system100that is shown to include a wellbore101formed in formation102for performing a treatment operation therein, such as fracturing the formation (also referred to herein as fracing or fracking), frac-packing, gravel packing, etc. and for determining, in real time or near real time, parameters of interest relating to such operations from sensors deployed in the system100and taking actions in response to such determined parameters of interest. The wellbore101is lined with a casing104, such as a string of jointed metal pipe sections, known in the art. The space or annulus103between the casing104and the wellbore101is filled with cement106. The system100is described herein in reference to a cased-hole; however, the concepts, apparatus and methods as described herein or with obvious modifications may equally be utilized for open holes. The particular embodiment ofFIG. 1is shown for selectively treating one or more zones in any selected sequence or order. However, wellbore101may be configured to perform other treatment or service operations, including, but not limited to, gravel packing and flooding a selected zone to move fluid in the zone toward a production well (not shown). The formation102is shown to include multiple zones Z1-Zn (also referred to as production zones) which may be fractured or treated for the production of hydrocarbons therefrom. Each such zone is shown to include perforations that extend from the casing104, through cement106and to a certain depth in the formation102. InFIG. 1, Zone Z1is shown to include perforations108a, Zone Z2to include perforations108b, and Zone includes Zn to include perforations108n. The perforations provide fluid passages for fracturing corresponding zones. The perforations also provide fluid passages for formation fluid150to flow from the formation102to the casing104. The wellbore101includes a sump packer109proximate to the bottom101aof the wellbore101. [open hole mentioned in paragraph 0009 below]

After casing, cementing, sump packer deployment, perforating and cleanup operations, the wellbore101is ready for treatment operations. Although system100is described in reference to fracturing and gravel packing production zones, the concepts, apparatus and methods as described herein or with obvious modifications may also be utilized for other well treatment operations, including, but not limited to, fracturing and gravel packing. Furthermore, the concepts, apparatus and methods disclosed herein may equally be utilized for open hole applications. The formation fluid105is at the formation pressure (P1) and the wellbore101is filled with a fluid152, such as completion fluid, which fluid provides hydrostatic pressure (P2) inside the wellbore101. The hydrostatic pressure P2is greater than the formation pressure P1along the depth of the wellbore101, which prevents flow of the fluid105from the formation102into the casing104and prevents blow-outs.

Still referring toFIG. 1, to fracture (treat) one or more zones Z1-Zn, a system assembly110is deployed in the wellbore101, which includes an outer string120and an inner string160placed inside the outer string120. The outer string120includes a pipe122and a number of devices associated with each of the zones Z1-Zn for performing treatment operations. In one non-limiting embodiment, the outer string120includes a lower packer124a, an upper packer124mand intermediate packers, such as packer124b. The lower packer124aisolates the sump packer109from hydraulic pressure exerted in the outer string120during fracturing and sand packing of the production zones Z1-Zn. In one aspect, packers124a-124mmay be hydraulically set or deployed packers. In another aspect, packers124a-124mmay be mechanically set or deployed. Still referring toFIG. 1, the outer string120further includes a screen adjacent to each zone Z1-Zn. For example, screen S1is shown placed adjacent to zone Z1, screen S2adjacent zone Z2and screen Sn adjacent to zone Zn. The lower packer124aand intermediate packer124bare deployed to isolate zone Z1from the remaining zones. Other zones are similarly isolated for treatment operations. Each packer has an associated packer setting or activation device, such as packer setting device125afor packer124a, packer setting device125bfor packer124band packer setting device125mfor packer124m. In the case of a hydraulically-activated packer, any suitable device known in the art, including a piston device, may be utilized as the hydraulic activation device, and in case of a mechanically-activated packer, the device may include a mechanical member that is moved to set the packer.

In one aspect, each screen has one or more associated flow control devices, such as sliding sleeve valves132aand132bshown on screen S1. Other screens have similar devices. The outer string120also includes, for each zone, a flow control device, referred to as the slurry outlet or a gravel exit, such as a sliding sleeve valve or another valve, uphole or above its corresponding screen to provide fluid communication between the inside120aof the outer string120and its corresponding zone.FIG. 1shows an exemplary slurry outlet140afor zone Z1between screen S1and the intermediate packer124b.

Still referring toFIG. 1, the inner string160includes an upper section160athat includes a tubular161made by joining pipe sections (such as drill pipe) and a lower section150(referred to as the service tool) connected to the upper section160a. The service tool150includes a pipe or tubular158, which may be a flush joint tubular, known in the art. The service tool150also may include an interface sub154attached to the bottom end161aof the tubular161to provide a connection for a communication link182in the tubular161to a communication link or line184in the service tool150, as described in more detail in reference toFIGS. 2-5. The phrase “communication link” or “communication line” means a link for communicating signals, data and/or power from one location to another. The communication link may be any suitable link, including, but not limited to, electric lines, fiber optic lines and other links, such as acoustic links or a combination of such links.

Still referring toFIG. 1, the service tool150includes a packer setting tool156for setting the upper packer124m. In a multi-zone well system, the tubular158may extend to over 3,000 feet. The service tool150further includes an opening shifting tool162and a closing shifting tool164along the lower end160aof the inner string160. The inner string160further may include a reversing valve166that facilitates the removal of treatment fluid from the wellbore after treating each zone, and an up-strain locating tool168for locating one or more locations uphole of a set-down location, such as a locations194bfor zone Z1when the inner string160is pulled uphole, and a set down tool or set down locating tool170. In one aspect, the set down tool170may be configured to locate each zone and then set down the inner string160at each such location for performing a treatment operation. The service tool150further includes a cross-over tool174(also referred to herein as the “frac port”) for providing a fluid path175between the inner string160and the outer string120. In one aspect, the frac port174also includes flow passages176therethrough, which passages may be gun-drilled through the frac port174to provide fluid communication between space172abelow the frac port174and space172babove the frac port174. The size of passages176, however, are sufficient to provide fluid flow and thus pressure communication between spaces172aand172b.

To perform a treatment operation in a particular zone, for example zone Z1, lower packer124aand upper packer124mare set or deployed. Setting the upper packer124mand lower packer124aanchors the outer string120inside the casing104. The production zone Z1is then isolated from all the other zones. To isolate zone Z1from the remaining zones Z2-Zn, the inner string160is manipulated to cause the opening tool164to open a monitoring valve133ain screen S1. The inner string160is then manipulated (moved up and/or down) inside the outer string120so that up-strain locating tool168locates a profile194b. The set down tool170is then manipulated to cause it to set down in the set down profile194a. When the set down tool170is set down at location194a, the frac port174is adjacent to the slurry outlet140a. The packer124bis then set to isolate zone Z1. Once the packer124bhas been set, frac sleeve140ais opened to supply slurry or another fluid to zone Z1to perform a fracturing or a treatment operation. Once zone Z1has been treated, the treatment fluid in the wellbore is removed by closing the reversing valve166to provide a fluid path from the surface in the space (or annulus) between the outer string120and the inner string160so that a fluid supplied from the surface into such annulus will cause the treatment fluid to move to the surface, which process is referred to as reverse circulation or reversing. After reverse circulation, the inner string160may then be moved to set down device170at another zone for treatment operations.

Still referring toFIG. 1, as described earlier, the inner string160includes a control line, also referred as the “communication link” for providing communication between a location in the service tool and the surface. The phrase “control line” or “communication link” means a link for communicating signals, data and/or power from one location to another. In one non-limiting embodiment, a communication link182, which may be a conductor, runs through the tubular161, referred to as the wired pipe in the art. Interface sub154connects the communication link182to a communication link184associated with the service tool150that runs to a control circuit185below the cross-over tool174. In one non-limiting embodiment, the communication link184passes through the packer setting tool156, as described in more detail in reference toFIG. 2. The communication link184then runs along the tubing158and then through the cross-over tool174, as described in more detail in reference toFIGS. 3 and 4. The communication link184then may pass other devices, such as the set down locating tool170, the up-strain locating tool168, reversing valve166and then along the tubing158below such devices. The control circuit185may be placed at any suitable location in the communication link184to receive signals from various sensors placed in the casing104, outer string120and the inner string160, as described in more detail in reference toFIG. 5. An exemplary packer setting tool200and a manner for running the communication link184through such a packer is described below in reference toFIG. 2.

FIG. 2shows an exemplary embodiment of a packer setting tool200configured to set a packer280.FIG. 2Ashows an exploded view of a section ofFIG. 2. Referring now toFIGS. 2 and 2A, in one aspect, the packer setting tool200may be utilized as the packer setting tool156for setting the upper packer125mshown in system100ofFIG. 1. The packer setting tool200includes an upper connection201that connects the packer setting tool200to the interface sub154(FIG. 1) and a lower connection202that connects the packer setting tool200to a connection pipe214downhole of the packer setting tool200. The packer setting tool200includes a flow through pipe210that provides a fluid passage212between the inner string (160,FIG. 1) and the surface. The packer setting tool200includes a connection device260that may include a number of spaced connection members, such as fingers262a,262b, etc., each such finger having a connection end, such as dogs264a,264b, which connect to or engage with a packer member281. Spacing between adjacent fingers may be utilized to run the communication link184,FIG. 1as described later. The packer setting tool200further includes a device270that enables the packer setting tool200to disengage from the packer280after the packer has been set. The packer setting tool200further includes a piston230outside the flow through pipe210and a shroud222over the piston230. The packer setting tool200also includes a movable outer sleeve220coupled to the piston230. Packer280further includes a movable packer setting member284, which member when moved causes the packer setting elements282to extend and engage with the casing (104,FIG. 1). To set the packer280against the casing, fluid under pressure is supplied to the piston230, which moves the piston230downhole (to the right inFIG. 2). The piston230moves the outer sleeve220to the right, which moves the packer setting member284to the right to set the packer elements282against the casing (104,FIG. 1). In one aspect, the communication link184may be routed or placed under the shroud222and over the piston and over a part of the outer sleeve220, as shown by label290aThe communication link184is then run through a bore221in the outer sleeve220as shown by label290band then between fingers262a,262bas shown by label290cand then outside214aof the connection pipe214and below the packer280, as shown by label290c. The communication link184then continues to run along the outside of the tubing158, as shown by label290d. The communication link184may be secured to the tubing158by any suitable mechanism, including but not limited to, clamps. Routing the communication link184through the outer sleeve220and the connection device260of the packer setting tool200and then between the ID of the packer280and the inner string as described herein enables the communication link184to pass from a location above the packer setting tool200to a location below the packer setting tool200without being exposed to high velocity frac slurry.

FIG. 3shows certain details of an exemplary cross-over tool300with the routing of the communication link184therethrough, according to one non-limiting embodiment of the disclosure. The cross-over tool300has an upper connection301that connects the cross-over tool to the pipe158and a lower connection302that connects the cross-over tool to a section303of the service tool150below the cross-over tool300. The cross-over tool300includes a cross-over assembly310for supplying a treatment fluid352to a production zone, as described in reference toFIG. 1. The treatment fluid352may be any suitable fluid for performing a treatment operation, including, but not limited to, a mixture of water or gel and a proppant, such as sand or manufactured proppants. In one non-limiting embodiment, the cross-over assembly310includes a housing320that includes a number of through holes322a,322b, etc., along the length of the body320. The body320further includes a number of radially spaced fluid inlets324a,324b, etc. (hidden inFIG. 3but depicted inFIG. 4), etc. around the body320. The body320further includes inserts330a,330b, etc. over the fluid inlets324a,324b, respectively, as shown in more detail in reference toFIG. 4. Each such insert includes a number of ports or fluid passages, such as ports340ain insert330a, ports340bin insert330b, etc. for supplying the treatment fluid152to the production zones, such as zones Z1-Zn shown onFIG. 1. Although the cross-over tool is shown to contain a number of elements, in aspects, it may only contain a frac port or another configuration know in the art.

Referring toFIGS. 3 and 4, in one aspect, the communication link184may be run through one or more holes, such as through holes322a,332b, etc. of the cross-over assembly310.FIG. 3shows communication link184running or passing through hole322afrom above the cross-over tool to below the cross-over tool. During a fracing operation, the treatment fluid158, which can be extremely abrasive due to the high velocity and presence of proppant and other chemicals, such as acids, passes through the ports340a,340b, etc. under high pressure and can damage control lines, such as communication link184. Routing the communication link184through passages322a,322b, prevents the communication link from coming in direct contact with the flow of the treatment fluid352through the cross-over tool300.

FIG. 5shows placement of exemplary sensors in system100for determining various parameters of interest during a treatment operation. The parameters of interest may include, but, are not limited to, weight or load on a device in the inner string160, tension on a device in the inner string160, a location in the inner string or the outer string, location temperature at one or more locations and/or a temperature profile, pressures at one or more locations and/or a pressure profile, micro-seismic signals produced by the flow of a treatment fluid into the formation and/or cracking of the formation during a fracing operation, one or more flow rates of the fluid, and opening or closing of a device, such a sleeve valve. In one non-limiting embodiment, the system100may include on the inner string one or more weight and tension sensors510, one or more pressure and temperature sensors P/T to determine the pressures and temperatures in the wellbore, one or more flow sensors520for determining the flow of a fluid, such as the flow of the treatment fluid152at one or more locations in the wellbore, and micro-seismic sensors530, such acoustic sensors, for determining sound wave during a fracing operation to determine the effectiveness of the fracing operation. In another aspect, tags544a,544b, etc., such as magnetic tags, may be placed spaced apart on or proximate to a moving member, such as a sleeve of a sliding sleeve valve140afor determining the movement of the sleeve and to ensure that the valve140ahas been correctly opened or closed. Tags, such as tags544a,544balso may be utilized to locate devices in the outer string120and/or to position a device, such as the set down tool170, in the inner string160at a selected location inside the outer string120. One or more tag detection sensors, such as sensors545, may be placed in the inner string to detect the presence of the tags in the outer string120. The tags may be of any suitable type, including, but not limited to, radiation tags, acoustic tags, electrical or resistive tags, and any other tags known in the art. Tags may also be utilized to locate other positions on the outer string120for any other purpose, including, but not limited to, use by the opening tool162, closing tool164, reverse valve166and the like. In another aspect, one or more suitable sensors, such as sensor550may be placed on the outside of the outer string120and a transmitter552may be placed on the inside of outer string120. The sensor may include a battery for power and transmits signals to a receiver554in the inner string160. Power to the control circuit185may be provided via a conductor in the communication link184by batteries186in the control circuit185.

Still referring toFIG. 5, the sensors520,530,544a,544b,550, etc. in the system100provide signals corresponding to their selected parameters of interest to the control circuit185. In one aspect, the control circuit185may preprocess the received signals, such as pre-amplifying and digitizing the received signals, and transmit the digitized signals via the control line to a surface controller590(such as a computer or computer-based system) for further processing and for providing real-time information to the operator for taking actions as necessary. In another aspect, the control circuit185may include a processor, such as a microprocessor586, a memory device587, such as a solid state memory and programmed instruction588accessible to the processor586for executing instructions contained in the programs588. The processor586may also be configured to receive signals from the surface controller590, process the signals from the downhole sensors and transmit information as directed by the surface controller. Although the embodiment ofFIG. 5is described in reference to a wire-type links (which for example may include electric conductor(s) or a fiber optic link(s)) run in or along the inner string160, other links, including acoustic links, may also be utilized for the purposes of this disclosure. For example, an acoustic link may include a transceiver580that receives signals from the control circuit185and transmits such signals via the inner string160to the surface. For long distances, repeaters582a,582b,582c, etc., may be placed in the inner string160to receive, amplify, condition and retransmit the signals to the next repeater or the surface as the case may be. Thus, in one aspect, the disclosure provides real-time two-way communication between a surface location and one or more locations in a wellbore via the inner string160.

The foregoing disclosure is directed to the certain exemplary embodiments and methods. Various modifications will be apparent to those skilled in the art. It is intended that all such modifications within the scope of the appended claims be embraced by the foregoing disclosure. The words “comprising” and “comprises” as used in the claims are to be interpreted to mean “including but not limited to”. Also, the abstract is not to be used to limit the scope of the claims.