Patent Publication Number: US-2022228446-A1

Title: Cementing and sand control system and methodology

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is based on and claims priority to U.S. Provisional Application Ser. No. 62/861,201, filed Jun. 13, 2019, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     In many well applications, casing is deployed downhole into a wellbore and cemented in place within the wellbore. Additionally, a sand control completion system is deployed down through the casing and positioned in a cased or open wellbore section to facilitate production of desired fluids. For example, the wellbore may be drilled into a subterranean formation containing hydrocarbon fluids, e.g. oil, and the sand control completion facilitates production of hydrocarbon fluids. Sometimes a gravel pack is provided downhole to help filter particulates from the inflowing hydrocarbon fluids before they enter the sand control completion system. 
     SUMMARY 
     In general, a system and methodology are provided for facilitating downhole operations, e.g. gravel packing and cementing operations, in a borehole. According to an embodiment, a service tool is releasably coupled with respect to a casing. The casing is used to run the service tool downhole into a borehole. In some embodiments, the casing is connected with a downhole completion, e.g. a sand control completion. A work string may then be conveyed downhole to the service tool and connected to the service tool. While connected to the work string, the service tool may be operated to perform desired downhole operations. 
     However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and: 
         FIG. 1  is a schematic illustration of an example of a well system deployed downhole with a service tool located within a casing and coupled to a work string, according to an embodiment of the disclosure; 
         FIG. 2  is a schematic illustration of the well system in which the service tool is conveyed downhole into a borehole, e.g. a wellbore, via the casing, according to an embodiment of the disclosure; 
         FIG. 3  is a schematic illustration similar to  FIG. 2  but showing the well system in a different operational position, according to an embodiment of the disclosure; 
         FIG. 4  a schematic illustration similar to  FIG. 3  but showing the well system in a different operational position, according to an embodiment of the disclosure; 
         FIG. 5  a schematic illustration similar to  FIG. 4  but showing the well system in a different operational position, according to an embodiment of the disclosure; 
         FIG. 6  a schematic illustration similar to  FIG. 5  but showing the well system in a different operational position, according to an embodiment of the disclosure 
         FIG. 7  a schematic illustration similar to  FIG. 6  but showing the well system in a different operational position, according to an embodiment of the disclosure; 
         FIG. 8  a schematic illustration similar to  FIG. 7  but showing the well system in a different operational position, according to an embodiment of the disclosure; 
         FIG. 9  a schematic illustration similar to  FIG. 8  but showing the well system in a different operational position, according to an embodiment of the disclosure; and 
         FIG. 10  a schematic illustration similar to  FIG. 9  but showing the well system in a different operational position, according to an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible. 
     The disclosure herein generally involves a methodology and system which facilitate downhole operations, e.g. cementing operations, gravel packing operations, sand control operations, and/or other downhole operations, in a borehole. By way of example, the methodology may comprise running a service tool with a casing. Subsequently, a work string may be connected to the service tool to enable operation of the service tool for various downhole operations, e.g. multizone downhole operations. 
     According to one embodiment, the casing is coupled with a downhole completion and the service tool is releasably coupled within the casing and/or downhole completion. The casing is used to run the service tool downhole into a borehole. In some embodiments, the downhole completion is in the form of a sand control completion, e.g. a multizone sand control completion. A work string may then be conveyed downhole to the service tool and connected to the service tool. While connected to the work string, the service tool may be operated to perform the desired downhole operations. 
     For example, a sand control completion may be coupled with the casing and the service tool may be releasably mounted inside. This overall assembly may be run downhole into a wellbore simultaneously. Subsequently the work string may be conveyed downhole and connected, e.g. latched, to the service tool to enable performance of various downhole operations. Examples of downhole operations include cementing operations and gravel packing operations. Once downhole operations are completed, the work string may be used to pull the service tool out of hole (e.g. out of the wellbore) to allow hydrocarbon production operations and/or other desired operations. 
     Depending on the application, the well system and methodology may be used to enable simultaneous cementing and placement of a sand control system. Such a sand control system may be utilized in various formation treatments, e.g. fracturing, proppant slurry injection, and/or gravel packing. The well system and methodology also facilitate treatment of one or multiple subterranean formations combined with cementing of a casing in a single trip. The casing may be in the form of various types of casings or liners and may be located above the treatment zone or zones. In these types of applications, the service tool may comprise a well treatment tool conveyed downhole via the casing and then coupled with the work string. The well treatment tool may be used in a variety of processes including circulating or squeeze type treatments and cleanup operations via reversing out excess slurry (e.g. cement or proppant) by reverse flow or by dumping the excess below. 
     Referring generally to  FIG. 1 , an example of a well system  30  is illustrated. In this embodiment, the well system  30  comprises a service tool  32  which may be run downhole into a borehole  34 , e.g. a wellbore, via a casing  36 . In some applications, the casing  36  may be connected with a downhole completion  38 . Additionally, the service tool  32  may be selectively connected with a work string  40  after the service tool  32  is conveyed downhole via casing  36 . 
     The borehole  34  may comprise a variety of wellbores or other boreholes and may include at least one open hole section  42  and at least one outer cased section  44  which is cased with an outer casing  46 . The outer casing  46  may be suspended from a casing hanger located at, for example, the surface. The at least one open hole section  42  may be drilled into a surrounding formation  48  and may extend through one or more well zones  50 . In some applications, the wellbore  34  may include deviated, e.g. horizontal, sections extending through the well zones  50 . The surrounding formation  48  may contain a reservoir of hydrocarbon fluids, e.g. oil and/or natural gas. 
     Additionally, the downhole completion  38  may be constructed in various configurations and with different types of components. By way of example, the downhole completion  38  may comprise a sand control completion  52  having at least one sand screen  54 , e.g. a plurality of sand screens  54 , separated by blanks  56  (blank pipe sections). The sand screens  54  filter out particulates from, for example, inflowing well fluid. Prior to running the sand control completion  52  downhole, the downhole completion  38  may undergo a displacement procedure according to one or more embodiments of the present disclosure. However, the displacement procedure may also be omitted without departing from the scope of the present disclosure. 
     The downhole completion  38  may comprise a variety of other components, such as a packer  58 , e.g. an open hole packer, a gravel pack sleeve assembly  60 , and a No-Go  62 . The gravel pack sleeve assembly  60  may comprise a shiftable gravel pack sleeve  64  which may be shifted within the service tool  32  between different gravel packing positions. In one or more embodiments of the present disclosure, the gravel pack sleeve  64  may be shrouded and centralized with a grease in the inner diameter (ID). The No-Go  62  may comprise a latch  66  or other retention feature for releasably coupling the service tool  32  with downhole completion  38  or other downhole system. The No-Go  62  or other suitable feature also may be connected to a washdown assembly  67 . These components and systems are provided as examples and the downhole completion  38 /sand control completion  52  may comprise various additional and/or other components and features. 
     Additionally, the downhole completion  38  may be deployed in various types of wellbores. For example, the downhole completion  38  may be in the form of sand control completion  52  with a plurality of sand screen assemblies having sand screens  54  positioned along wellbore  34 , e.g. along a horizontal section of wellbore  34 . The sand screens  54  may be separated by a plurality of the packers  58  to create a plurality of corresponding isolated well zones  50  along the horizontal section of wellbore  34 . 
     In the illustrated embodiment, the casing  36  also may comprise or may be combined with various features. By way of example, the casing  36  and/or downhole completion  38  may include or may be coupled with a cement sleeve assembly  68 . The cement sleeve assembly  68  may have a sleeve  70  which is shiftable by the service tool  32  between different cementing positions. In one or more embodiments of the present disclosure, the cement sleeve  70  may be shrouded and centralized with a grease in the ID. Depending on parameters of a given downhole operation, the casing  36  and/or downhole completion  38  may comprise various additional components or other types of components arranged in configurations to facilitate the given downhole operation. 
     Referring again to  FIG. 1 , the service tool  32  also may have a variety of components and configurations. By way of example, the service tool  32  may comprise a circulation assembly  72  combined with a wash pipe assembly  74 . According to an embodiment, the circulation assembly  72  may comprise tubing  76  having a spacer string  78 . Crossover ports  80  may be positioned along the tubing  76 , e.g. in a port body, to enable fluid communication between an interior passage  82  and an exterior of the circulation assembly  72 . The crossover ports  80  may be selectively opened and closed via shifting of a sleeve  84 . 
     In the illustrated example, the circulation assembly  72  also comprises return ports  86  which cooperate with an annular check valve  88 . The circulation assembly  72  also may include a wash down ball seat  90  positioned to receive a ball for blocking flow along the interior passage  82 . Various seals  92  may be positioned along the exterior of tubing  76  to enable selective sealing with portions of the surrounding structures, e.g. portions of the surrounding downhole completion  38  and/or casing  36 . By way of example, the seals  92  may comprise upper seals  94 , e.g. swab cups, and lower seals  96 , e.g. swab cups. Depending on the application, various types of shifters  98  may be positioned along the exterior of the circulation assembly  72  and/or wash pipe assembly  74  to enable shifting of external components, e.g. sleeves  64 ,  70 , during movement of service tool  32 . 
     The wash pipe assembly  74  also may comprise many types of features depending on the parameters of a given environment and/or application. By way of example, the wash pipe assembly  74  may comprise a space out joint  100  and a seal assembly  102  positioned to selectively form a seal with a surrounding component of, for example, downhole completion  38 . Wash pipe assembly  74  also may comprise a variety of other components or features, such as shifters  98 , wash pipe joints and diverter valves. 
     In the illustrated example, the service tool  32  also comprises a latch profile  104  which may be coupled to tubing  76  of circulation assembly  72 . In some embodiments, the latch profile  104  may be combined with a polished bore receptacle  106 . The latch profile  104  is configured for coupling/engagement with a corresponding anchor latch  108  of work string  40 . 
     It should be noted that work string  40  also may comprise a variety of components and features selected according to the parameters of a given operation and environment. In various applications, the work string  40  comprises drill pipe  110  or other suitable pipe connected to anchor latch  108  for engagement with service tool  32  after service tool  32  is conveyed downhole via casing  36 . 
     Referring generally to  FIGS. 2-10 , an operational example is provided. In this embodiment, the service tool  32  is releasably coupled within casing  36 , e.g. at least partially within casing  36 , as illustrated in  FIG. 2 . As illustrated, the service tool  32  may be positioned inside both casing  32  and completion  38  while being releasably coupled with at least one of the casing  32  and completion  38 . By way of example, the service tool  32  may be releasably coupled within casing  36  via latch  66  of downhole completion  38 . 
     In this configuration (see  FIG. 2 ), the service tool  32  is run in hole via casing  36 . Once positioned at a desired location within borehole/wellbore  34 , washdown fluid may be pumped down through the service tool  32  and up through the annulus surrounding completion  38  to displace fluid in the open hole annulus, as represented by arrows  112 . While the service tool  32  is positioned at the desired location in borehole  34 , the work string  40  may be run in hole and connected to the service tool  32 , as illustrated in  FIG. 3 . 
     By way of example, the work string  40  may be connected to service tool  32  by engaging anchor latch  108  with latch profile  106 . As discussed above, the work string  40  may comprise drill pipe  110  or other suitable tubing along with appropriate components or features for a given operation. It should be noted the washdown represented by arrows  112  could be performed after connection of the work string  40  with service tool  32 . 
     Once the work string  40  is connected to service tool  32 , the service tool  32  may be operated to perform desired downhole operations, e.g. gravel packing operations, cementing operations, and/or other desired downhole operations. By way of example, the service tool  32  may be used for certain operations by dropping a ball  114  down through the interior of work string  40  and through interior passage  82  until seating against ball seat  90  as illustrated in  FIG. 4 . For this operation, the service tool  32  is lifted via work string  40  to the position illustrated in  FIG. 4  such that top seals  94  are sealed against interior features of casing  36  and bottom seals  96  are sealed against features of downhole completion  38  so as to isolate the crossover ports  80 . 
     When positioned against ball seat  90 , the ball  114  blocks flow of fluid down through the interior of service tool  32  beneath ball  114 . Accordingly, after the ball  114  is seated, actuation fluid may be directed down through work string  40  and through interior passage  82  until being forced outwardly through crossover ports  80  as indicated by arrows  116 . Because seals  94 ,  96  are sealed against their surrounding features, the actuation fluid can be pressurized to set packer  58 , thus isolating the region/annulus around downhole completion  38 . 
     In some embodiments, a gravel packing operation may then be performed, as illustrated in  FIG. 5 . For example, the service tool  32  may be moved downhole via work string  40  to the position illustrated in  FIG. 5  such that seals  94 ,  96  seal against the interior of completion  38  above and below gravel pack sleeve assembly  60 . This allows a gravel slurry (represented by arrows  118 ) to be directed down through the interior of work string  40  and along interior passage  82  until being forced out through crossover ports  80  and gravel pack sleeve assembly  60  into the annulus surrounding downhole completion  38 . Return fluids (represented by arrows  120 ) can flow up through wash pipe assembly  74  and through appropriate porting of service tool  32  until exiting through return ports  86  into the annulus between service tool  32 /work string  40  and the surrounding casing  36 . The return fluids may flow uphole along this annulus until reaching the surface. 
     Following the gravel packing operation, the seals  94 ,  96  may be dumped (i.e. moved to a non-sealing position) by lifting the service tool  32  via work string  40  as illustrated in  FIG. 6 . In this position a reverse flow of fluid may be directed along the exterior of service tool  32 , in through crossover ports  80 , and up through interior passage  82  and further up through the interior of work string  40  as illustrated by arrows  122  in  FIG. 6 . 
     After reversing out the remaining slurry, the service tool  32  may be lifted in the up hole direction via work string  40  to a position as illustrated in  FIG. 7  so as to enable opening of cement sleeve  70 . Once the service tool  32  is positioned as illustrated in  FIG. 7 , the work string  40  may again be used to move service tool  32  downwardly so the appropriate shifter  98  may shift cementing sleeve  70  to an open position, as illustrated in  FIG. 8 . In the position shown in  FIG. 8 , the seals  94 ,  96  are once again sealed against their surrounding structures so as to isolate crossover ports  80 . 
     This allows a cementing material to be directed down through the interior of work string  40  and along interior passage  82  until being forced out through crossover ports  80  and cement sleeve assembly  68  into the annulus surrounding casing  36  as indicated by arrows  124 . The cement material flows upwardly into the annulus between casing  36  and the outer casing  46 . 
     Once sufficient cement is deposited, the service tool  32  may be lifted via work string  40  to the position illustrated in  FIG. 9  in which the lower seals  96  remain sealed against the surrounding structure of casing  36 . This allows the remaining cement in service tool  32  and the interior of work string  40  to be reversed out by directing fluid down through the annulus between casing  36  and service tool  32 , in through crossover ports  80 , and up through interior passage  82 , as represented by arrows  126  in  FIG. 9 . After completing the cementing operation, the service tool  32  may be pulled out of hole via work string  40  as illustrated in  FIG. 10 . 
     The downhole operations illustrated in  FIGS. 2-10  provide examples of how the service tool  32  may be run in hole on casing  36  and then operated to perform various downhole operations. However, the overall well system  30  may be used in various configurations to perform a variety of downhole operations. 
     As described herein, the sand control completion  52  may be combined with the cementing assembly, e.g. cement sleeve assembly  68 , and run downhole with service tool  32  via casing  36 . Depending on the parameters of a given application, the assembly may be run in hole in mud or brine. Subsequently, the work string  40  may be run in hole and connected to the service tool  32  for displacement of fluid in the open hole section  42 . 
     The packer or packers  58  may then be set and a gravel pack operation may be performed in the open hole section  42  followed by the appropriate reverse out procedure. (In some applications, the sand control completion  52  may be a stand-alone completion and the gravel packing operation may be omitted.) After gravel packing, the cementing operation may be performed as described above and then the service tool  32  may be pulled out of hole. However, the deployment of service tool  32  and operation of service tool  32  may have variations to accommodate parameters of desired downhole operations. 
     According to another example, the methodology may be employed for completing a well with multiple zones in a single trip and with a single pumping treatment. In this embodiment, the sand control completion  52  may be combined with the cementing assembly, e.g. cement sleeve assembly  68 , and run downhole with service tool  32  via casing  36 . Subsequently, the work string  40  may be run in hole and connected to the service tool  32  for displacement of fluid in the open hole section  42 . 
     A plurality of packers  58  may then be set to establish well zones  50  which may be treated in one treatment using shunted sand screens  54  and shunted open hole packers  58 . Following the well treatment, the cementing operation may be performed as described above and then the service tool  32  may be pulled out of hole. 
     According to another example, the methodology may be employed for completing a well with multiple zones (located in the open hole section) in a single trip and with multiple pumping treatments. In this embodiment, the sand control completion  52  may be combined with the cementing assembly, e.g. cement sleeve assembly  68 , and run downhole with service tool  32  via casing  36 . Subsequently, the work string  40  may be run in hole and connected to the service tool  32  for displacement of fluid in the open hole section  42 . 
     A plurality of packers  58  may then be set to establish well zones  50 . The individual well zones  50  may each be treated according to a suitable sequence which may include: placing the service tool  32  across a screen assembly to open a screen sleeve; placing the service tool across a gravel pack assembly to open the corresponding gravel pack sleeve  64  and to position the service tool  32  for performance of the desired treatment in that zone  50 ; treating the given zone  50 ; reversing out and closing the gravel pack sleeve  64 ; dumping the seals  94 ,  96 ; and closing the screen valve. Following the well treatments of zones  50 , the cementing operation may be performed as described above and then the service tool  32  may be pulled out of hole. 
     According to another example, the methodology may be employed for completing a well with multiple zones (located in cased and open hole sections) in a single trip and with multiple pumping treatments. In this embodiment, the sand control completion  52  may be combined with the cementing assembly, e.g. cement sleeve assembly  68 , and run downhole with service tool  32  via casing  36 . Subsequently, the work string  40  may be run in hole and connected to the service tool  32  for displacement of fluid in the open hole section  42 . 
     A plurality of packers  58  may then be set to establish well zones  50  along cased and open hole sections of the wellbore  34 . The individual well zones  50  may each be treated according to a suitable sequence which may include: placing the service tool  32  across a screen assembly to open a screen sleeve; placing the service tool across a gravel pack assembly to open the corresponding gravel pack sleeve  64  and to position the service tool  32  for performance of the desired treatment in that zone  50 ; treating the given zone  50 ; reversing out and closing the gravel pack sleeve  64 ; dumping the seals  94 ,  96 ; and closing the screen valve. Following the well treatment of zones  50 , an initial cementing operation may be performed independently through a cement sleeve while taking returns through a casing/liner return sleeve and then closing the given casing/liner cementing sleeve following this particular cementing operation. 
     The service tool  32  may then be placed adjacent a given cementing section treatment sleeve so as to open the sleeve to a treat position. A treatment operation, e.g. a fracturing operation, may then be performed through the treatment sleeve. Subsequently, the treatment sleeve is closed and the service tool  32  is moved to the next cementing zone for repeating of the cementing operation in that zone. The service tool  32  may then be pulled out of hole. Additionally, a suitable shifting tool may be run in hole to move each treatment sleeve to a production position for production of the desired hydrocarbon fluids. 
     It should be noted, however, the service tool  32  may be deployed via casing  36  for performance of various downhole operations in single zones or plural zones along the borehole  34 . Additionally, the various systems and components of well system  30  may be adjusted according to the parameters of the downhole environment and/or operations. 
     For example, the completion string comprising completion  38  may include various types of washdown assemblies  67  and screens  54 , e.g. screens with or without mud protection. Additionally, the completion  38  may comprise various types of gravel pack sleeve assemblies  60  with at least one port and with at least one corresponding sleeve  64  as well as position locators. The completion  38  also may comprise an individual packer  58  or a plurality of the packers  58 . In some embodiments, the completion  38  may include the cement sleeve assembly  68  which may comprise at least one cement port with corresponding sleeves  70  as well as position locators. 
     Similarly, the service tool  32  may include various types and configurations of components. For example, the service tool  32  may include various types of shifters  98  configured and oriented for interaction with corresponding sleeves and locators. Additionally, various configurations of crossover ports  80 , crossover port bodies, and seals  94 ,  96  may be employed to achieve a desired sealing and fluid flow path. 
     For example, the crossover ports  80  and seals  94 ,  96  may be arranged to provide a path for circulating fluid down the work string  40  while taking returns through the screens  54  and back through appropriate porting in the service tool  32  to the annulus between the work string  40  and the casing  36 . The crossover ports  80  and seals  94 ,  96  also may be arranged to provide a path to circulate fluid down through work string  40  and then up through the surrounding annulus or vice versa. In some embodiments, a path for circulating fluid may be routed down through the work string  40  to the bottom of the wash pipe assembly  74  and up through the annulus surrounding the completion  38  to the surface. The service tool components also may be arranged to provide a path for circulating fluid down through the work string  40  to the bottom of the wash pipe assembly  74  after conveying the gravel pack. 
     In some embodiments, the crossover ports, seals  94 ,  96 , and other service tool components may be arranged to eliminate swabbing by keeping constant hydrostatic communication with the formation during movements of service tool  32 . Accordingly, the components and the arrangement of components of service tool  32  may be adjusted according to the desired fluid circulation and operation of the service tool  32  for given downhole applications. 
     Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.