Patent Publication Number: US-11649694-B2

Title: Open hole multi-zone single trip completion system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 63/167,368, filed Mar. 29, 2021, the contents of which are incorporated by reference herein in their entirety. 
    
    
     BACKGROUND 
     In the drilling and completion industry, completions are constructed in a bore hole to facilitate resource recovery. A lower completion is usually run in on a service string. Fluids are circulated through the bottom of the completion to remove debris and maintain well control. In a cased bore hole, a sump packer is often arranged at a lower portion of a casing tubular and installed prior to running the completion string. The completion string can be sealed into the sump packer. At this point, pressure may be built up within the completion to set packers and/or activate other tools. In an open hole environment, there is no casing tubular at the bottom portion of the bore hole and no sump packer. 
     In an open hole environment, the completion is run in with fluids passing through the bottom to remove debris and maintain well control. Once the completion is in position, objects (such as a ball) are often circulated down hole via the service string to sequentially activate packers and/or other components. After activation, the objects may require circulation out of the service string to remove the obstruction in the tubular bore and continue subsequent operations such as stimulation or sand control operations. Removing an object may include reverse flow, forcing the object passed an object seat, or degrading the object to open the flow path. The use of objects is a time-consuming process that increases well operations. The industry would welcome a system for activating components in an open hole environment that would reduce rig time before additional operations can commence. 
     SUMMARY 
     Disclosed is a multi-zone single trip open hole completion system including an outer tubular assembly including an uphole end, a downhole end, and an intermediate portion, an inner tubular assembly, an anchor arranged on the outer tubular assembly, an anchor setting assembly provided on one of the outer tubular assembly and the inner tubular assembly, the anchor setting assembly being operable to selectively set the anchor, an isolation flow path in the outer tubular, an object seat arranged on the inner tubular and the outer tubular. The object seat is receptive of an object that blocks flow through the one of the inner tubular and the outer tubular. A remotely operated valve is arranged in the tubular. The remotely operated valve is operable to close fluid flow through the tubular. An isolation packer is arranged along the intermediate portion. Closing the remotely operated valve enables the anchor, and the isolation packer to be set. 
     Also disclosed is a multi-zone single trip open hole completion system including a tubular assembly including an uphole end, a downhole end, and an intermediate portion, an anchor arranged on the tubular assembly, and a remotely operated valve arranged in the tubular assembly. The remotely is operated valve being operable to close the downhole end of the tubular assembly to fluid flow. An isolation packer is arranged along the intermediate portion, wherein closing the remotely operated valve enables the anchor and the isolation packer to be set. 
     Further disclosed is a multi-zone single trip open hole completion system including an inner tubular assembly, an outer tubular assembly, an anchor coupled to the outer tubular, an anchor setting assembly operable to selectively activate the anchor, an isolation flow path in the outer tubular, and an object seat arranged on the outer tubular assembly. The object seat is being receptive of an object to block flow through the outer tubular assembly. An isolation packer is arranged along the intermediate portion, wherein bypassing the object seat enables the isolation packer to be set. 
     Still further disclosed is a method of forming a multi-zone single trip open hole completion including running a multi-zone single trip open hole completion assembly including an anchor and an isolation packer into an open hole well bore to a selected depth, flowing fluid through a bottom hole assembly (BZA) of the completion assembly during run in, closing a remotely operated valve arranged in the BZA to stop the flow of fluid, and setting the anchor and the isolation packer by applying pressure to the completion assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG.  1    depicts a multi-zone single trip completion system with an open hole lower zone assembly in a run in configuration, in accordance with a non-limiting example; 
         FIG.  2    depicts a bottom hole assembly including a remotely actuated well isolation valve of the multi-zone single trip open hole completion assembly of  FIG.  1   , in accordance with a non-limiting example; 
         FIG.  3    depicts the multi-zone single trip open hole completion system after closing the remotely actuated well isolation valve, in accordance with a non-limiting example; 
         FIG.  4    depicts the multi-zone single trip open hole completion system of  FIG.  3    after setting a top anchor, and a plurality of isolation packers, in accordance with a non-limiting example; 
         FIG.  5    depicts dropping an object into an anchor setting assembly of the multi-zone single trip open hole completion system to set the top anchor if the remotely actuated well isolation valve fails to close, in accordance with a non-limiting example; 
         FIG.  6    depicts exposing a bypass flow path in the anchor setting assembly, in accordance with a non-limiting example; 
         FIG.  7    depicts a service string being picked up to close the isolation valve, in accordance with a non-limiting example; 
         FIG.  8    depicts flowing fluid through the bypass flow path to set, the plurality of isolation packers after the service string is set back down, in accordance with a non-limiting example; 
         FIG.  9    is a cross-sectional view of the anchor setting assembly in a run in configuration, in accordance with a non-limiting example; 
         FIG.  10    depicts the anchor setting assembly of  FIG.  9    after landing an object to set the top anchor, in accordance with a non-limiting example; 
         FIG.  11    depicts the anchor setting assembly of  FIG.  10    after opening the bypass flow path, in accordance with a non-limiting example; 
         FIG.  12    depicts a multi-zone single trip completion system with an open hole lower zone assembly in a run in configuration, in accordance with another non-limiting example; and 
         FIG.  13    depicts the multi-zone single trip open hole completion system of  FIG.  12    after closing the remotely actuated well isolation valve, in accordance with a non-limiting example. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     A multi-zone single trip open hole completion system is generally indicated at  10  in  FIG.  1   . When installed, the multi-zone single trip open hole completion assembly  10  is supported at a casing tubular  14  arranged in a well bore  16 . Casing tubular  14  includes a terminal end  18 , below which is an open bore hole. In a non-limiting example, multi-zone single trip open hole completion assembly  10  includes an outer string assembly, shown in the form of an outer tubular assembly  24  having an uphole end  28  that is arranged within casing tubular  14 , a downhole end  30  arranged within the open bore hole of well bore  16 , and an intermediate portion  32 . 
     In a non-limiting example, multi-zone single trip open hole completion assembly  10  includes an anchor  36  arranged at uphole end  28 . Anchor  36  selectively engages with an inner surface (not-separately labeled) of casing tubular  14  to support outer tubular assembly  24 . Anchor  36  does not seal against the inner surface of casing tubular  14  and may take the form of an assembly that contains slips  38 . An anchor setting assembly  42  may be arranged adjacent anchor  36 . Anchor setting assembly  42  may be employed to set anchor  36  as will be detailed herein. 
     Multi-zone single trip open hole completion assembly  10  also include a bottom zone assembly (BZA)  46  arranged at downhole end  30  and a plurality of isolation packers  50   a ,  50   b ,  50   c , and  50   d  arranged along intermediate portion  32 . The number and location of isolation packers  50   a - d  may vary. Production screens, such as shown at  54   a ,  54   b , and  54   c  may be arranged between adjacent ones of isolation packers  50   a - d . Further, outer tubular system  24  may also support a number of slurry outlets  56   a ,  56   b , and  56   c  that may be associated with each production screen  51   a - c . Slurry outlets  56   a - c  may be used, for example, during a gravel pack operation. With this arrangement, well bore  16  may be divided into a number of production zones that are isolated from one another. 
     Reference will now follow to  FIG.  2   , with continued reference to  FIG.  1   , in describing BZA  46  in accordance with a non-limiting example. BZA  46  includes a housing  64  that surrounds an isolation flow path, which, in a non-limiting example, may take the form of an isolation valve  66 . It should be understood that the isolation flow path may take on various formed including one or more orifices that may be selectively blocked. BZA  46  is also shown to include and a float shoe  70 . 
     In a non-limiting example, a remotely operated valve  74  is arranged between isolation valve  66  and float shoe  70 . At this point, it should be understood that remotely operated valve  74  may take on various forms including an electronically operated valve or an electrically operated valve. An electronically operated valve may include, for example, integrated circuits, processors and/or the like. Remotely operated valve  74  may also be a simple electrically operated device that is devoid of processor, circuitry, and the like. Remotely operated valve  74  may also take on other forms including various valve types, including rupture discs that may be activated from the surface with and/or without the need for mechanical intervention. A flow path  77  is defined between housing  64  and outer tubular assembly  24 . A plug  78  is arranged at a terminal end (not separately labeled) of outer tubular assembly  24 . Plug  78  blocks off the terminal end of outer tubular assembly  24  forcing fluid to flow through isolation valve  66 . While described as using plug  78  to force fluid through isolation valve  66  into flow path  77 , other systems may also be used to allow pressure to be built up in outer tubular assembly  24  such as seal bores, other plugs, shifting sleeves, shifting pistons and the like are also contemplated. 
     Flow path  77  allows fluids from the surface to flow through multi-zone single trip open hole completion assembly  10  and out from float shoe  70  during run in. In a non-limiting example, multi-zone single trip open hole completion assembly  10  may be run in on an inner tubular assembly or service string  80  that may include multiple selective shifting tools, such as shown at  82 . Shifting tools  82  may include a closing tool  84  that may mechanically close isolation valve  66  and an opening tool  86  that may mechanically open isolation valve  66 . 
     In a non-limiting example, multi-zone single trip open hole completion assembly  10  is run into well bore  16  to a selected depth. During run-in, remotely operated valve  74  is open allowing fluids to flow through isolation valve  66  along flow path  77  and out through float shoe  70 . This forward flow of fluid helps control debris and maintain well control. Once at the selected depth, a signal is sent from, for example, a surface control station (not shown) to remotely operated valve  74 . The signal may take on many forms and may be an electric signal passed along a control line, fluid pulses, acoustic signals, a signal passed through a formation or the like. In response to receiving the signal, remotely operated valve  74  closes as shown in  FIG.  3   . 
     Once remotely operated valve  74  closes, pressure may be applied to outer tubular assembly  24  which, in a non-limiting example, sets, as a group, anchor  36  and each of the plurality of isolation packers  50   a - d  and disconnects inner tubular assembly  80  from outer tubular assembly  24  as shown in  FIG.  4   . Setting isolation packers  50   a -d as a group creates the multiple isolated production zones (not separately labeled) and reduces any likelihood that crossflow may exist between adjacent production zones. Further, setting anchor  36  and the plurality of isolation packers  50   a - d  with pressure eliminates the need to circulate an object into and out from the multi-zone single trip open hole completion assembly  10  thereby saving rig time. 
     In the event that remotely operated valve  74  fails to close as detected by, for example, an inability of outer tubular assembly  24  to hold pressure, multi-zone single trip open hole completion assembly  10  using, for example, anchor setting assembly  42  may still be effective as shown in  FIGS.  5 - 8   . 
     In a non-limiting example, if remotely operated valve  74  fails to close flow path  77 , an object, such as a drop ball  94  may be introduced into inner tubular assembly  80  as shown in  FIG.  5   . Object  94  is pumped down to anchor setting assembly  42 . As will be detailed herein, pressure is applied to object  94  causes anchor setting assembly  42  to set anchor  36  and disconnect inner tubular assembly  80  from outer tubular assembly  24  as shown in  FIG.  6   . Once anchor  36  is set, service string  80  may be picked up to close isolation valve  66  and open a bypass flow path as shown in  FIG.  7    as will be detailed herein. 
     Service string  80  is set back down as shown in  FIG.  8    and pressure applied to outer tubular assembly  24  causing isolation packers  50   a - d  to set, as a group to establish multiple production zones (not separately labeled). It should be understood that the object may be introduced into the inner tubular assembly or service string  80  or outer tubular assembly  24  to block a flow path and generate pressure to set the anchor. It should also be understood that while shown as being part of service string  80  and located an uphole end  28  of outer tubular assembly  24 , anchor setting assembly  42  may be arranged in various locations. While isolation is shown to be a valve, other systems for closing inner tubular assembly  80  are also contemplated including straddling seals, plugging downhole end  30 , dropping an object  94  and the like. 
     Reference will now follow to  FIGS.  9 - 11    in describing anchor setting assembly  42  in accordance with a non-limiting example. Anchor setting assembly  42  includes a body  96  defining a conduit  98 . A flow control system  99  is arranged in body  96 . Flow control system  99  may include an object seat  100  that may support object  94  and is surrounded by a sleeve  101 . As will be detailed herein, object seat  100  may be selectively shifted relative to sleeve  101 . Object seat  100  includes a first opening  104  aligned with conduit  98  and a plurality of second radially disposed openings  106 . Object seat  100  is also shown to include an object capture member  110 . Object capture member  110  prevents object  94  from moving off of object seat  100 . In a non-limiting example, sleeve  101  includes an enlarged diameter portion  114  that forms a bypass flow path  117  as will be detailed herein. 
     It should be understood that while shown as being part of anchor setting assembly  42 , flow control system  99  may be located in alternative positions such as at downhole end  30  of outer tubular assembly  24  or within service string  80 . Anchor setting assembly  42  may set anchor  36  before the production zones are isolated one from another. At this point it should be understood that while flow control system  99  was described as including an object seat that may be receptive of an object which is later bypassed, other systems for selectively blocking and unblocking inner tubular  80 , outer tubular assembly  24  and/or completion assembly  10  are also contemplated. For example, a second remotely operated valve could be deployed on inner tubular  80 . The second remotely operated valve could be operated with a signal from surface or manipulation of the inner tubular assembly  10 . 
     During run in, anchor conduit  98  is unobstructed such as shown in  FIG.  9   . If remotely operated valve  74  does not activate, a flow control device, such as an object  94  is introduced into inner tubular assembly  80  and landed on object seat  100  blocking conduit  98  as shown in  FIG.  10   . Pressure is applied to object  94  causing anchor  36  to engage casing tubular  14 . After anchor  36  is set, service string  80  is picked up thereby shifting sleeve  101  upwardly such that, in addition to closing isolation valve  66 , enlarged diameter portion  114  surrounds object  94  as shown in  FIG.  11   . In this position, the plurality of second radially disposed openings  106  are exposed to bypass flow path  117  to reestablish a fluid flow path thereby allowing fluid to flow past object  94  toward float shoe  70 . With isolation valve  66  being closed, pressure may build in outer tubular assembly  24 . The pressure may be used to set the isolation packers. 
     Reference will now follow to  FIGS.  12  and  13   , wherein like reference numbers represent corresponding parts in the respective views, in describing an isolation valve  200  in accordance with another non-limiting example. Instead of an isolation valve incorporated into BZA  46 , isolation valve  200  may take the form of a plug  210  that is mounted to a terminal end (not separately labeled) of service string  80 . Plug  210  may be positioned below shifting tools  82 . In a non-limiting example, isolation valve  200  may transition between an open position as shown in  FIG.  11    to a closed position, as shown in  FIG.  12   . In the closed position, plug  210  may seal against an internal surface  220  of outer tubular assembly  24  shutting off flow through float shoe  70 . At this point it should be understood that the exemplary embodiments describe a system for setting an anchor and setting, as a group, a plurality of isolation packers in an open hole well bore without the need to circulate and or reverse circulate multiple objects or for multiple trips into the well bore. After the packers are set, service string  80  may be shifted upwardly to open each zone to production or perform other operations such as stimulation without concern that cross flow will occur. Eliminating cross flow will reduce the potential for reservoir damage or the introduction of debris into the wellbore. Prior to setting the isolation packers, hydrostatic pressure is maintained on the production zones by use of a non-sealing anchor. Other methods of maintaining hydrostatic pressure on the formation zones may also be employed such as additional sleeves or bypass flow paths. 
     Set forth below are some embodiments of the foregoing disclosure: 
     Embodiment 1. A multi-zone single trip open hole completion system comprising: an outer tubular assembly including an uphole end, a downhole end, and an intermediate portion; an inner tubular assembly; an anchor arranged on the outer tubular assembly; an anchor setting assembly provided on one of the outer tubular assembly and the inner tubular assembly, the anchor setting assembly being operable to selectively set the anchor; an isolation flow path in the outer tubular; a flow control system arranged on the inner tubular assembly, the flow control system selectively blocking flow through the inner tubular assembly; a remotely operated valve arranged in one of the inner tubular assembly and the outer tubular assembly, the remotely operated valve being operable to close fluid flow through the tubular; and an isolation packer arranged along the intermediate portion, wherein closing the remotely operated valve enables the anchor, and the isolation packer to be set. 
     Embodiment 2. A multi-zone single trip open hole completion system comprising: a tubular assembly including an uphole end, a downhole end, and an intermediate portion; an anchor arranged on the tubular assembly; a remotely operated valve arranged in the tubular assembly, the remotely operated valve being operable to close the downhole end of the tubular assembly to fluid flow; and an isolation packer arranged along the intermediate portion, wherein closing the remotely operated valve enables the anchor and the isolation packer to be set. 
     Embodiment 3. The multi-zone single trip open hole completion system according to any prior embodiment, further comprising: an isolation flow path including an isolation valve arranged in the tubular assembly. 
     Embodiment 4. The multi-zone single trip open hole completion system according to any prior embodiment, wherein the anchor is a non-sealing anchor that does not form a seal with a surface of the wellbore. 
     Embodiment 5. The multi-zone single trip open hole completion system according to any prior embodiment, further comprising: an anchor setting assembly arranged in the tubular at the anchor. 
     Embodiment 6. The multi-zone single trip open hole completions system according to any prior embodiment, wherein, the flow control system includes an object seat and a selectively activatable bypass flow path. 
     Embodiment 7. A multi-zone single trip open hole completion system comprising: an inner tubular assembly; an outer tubular assembly; an anchor arranged on the outer tubular; an anchor setting assembly operable to selectively activate the anchor; an isolation flow path in the outer tubular assembly; a flow control system arranged on the inner tubular assembly, the flow control system selectively blocking flow through the inner tubular assembly; and an isolation packer arranged along the outer tubular, wherein the flow control system includes a bypass that enables the isolation packer to be set. 
     Embodiment 8. The multi-zone single trip open hole completion system according to any prior embodiment, wherein the anchor is a non-sealing anchor that does not form a seal with a surface of the wellbore. 
     Embodiment 9. The multi-zone single trip open hole completion system according to any prior embodiment, further comprising: an isolation valve arranged above the downhole end of the tubular. 
     Embodiment 10. The multi-zone single trip open hole completion system according to any prior embodiment, wherein the flow control system includes an object seat. 
     Embodiment 11. The multi-zone single trip open hole completion system according to any prior embodiment, wherein the flow control system forms part of the anchor setting assembly and the object seat includes an object capture member. 
     Embodiment 12. A method of forming a multi-zone single trip open hole completion comprising: running a multi-zone single trip open hole completion assembly including an anchor and an isolation packer into an open hole well bore to a selected depth; flowing fluid through a bottom hole assembly (BZA) of the completion assembly during run in; closing a remotely operated valve arranged in the BZA to stop the flow of fluid; and setting the anchor and the isolation packer by applying pressure to the completion assembly. 
     Embodiment 13. The method according to any prior embodiment, further comprising: detecting that the remotely operated valve did not function; and setting the anchor with a flow control system that blocks flow through an inner tubular assembly. 
     Embodiment 14. The method according to any prior embodiment, further comprising: opening a bypass flow path to bypass the flow control system. 
     Embodiment 15. The method according to any prior embodiment, further comprising: closing an isolation flow path in the completion assembly. 
     Embodiment 16. The method according to any prior embodiment, further comprising: flowing additional fluid through the bypass flow path to set the isolation packer. 
     Embodiment 17. The method according to any prior embodiment, wherein when setting the anchor occurs before production zones in the open hole well bore are isolated one from another. 
     Embodiment 18. The method according to any prior embodiment, wherein setting the anchor includes engaging the anchor with surface of a casing tubular. 
     Embodiment 19. The method according to any prior embodiment, wherein setting the isolation packer includes setting a plurality of isolation packers. 
     Embodiment 20. The method according to any prior embodiment, wherein setting the plurality of isolation packers includes setting at least one of the plurality of isolation packers against the casing tubular and another of the plurality of isolation packers against a surface of the open hole well bore. 
     Embodiment 21. The method according to any prior embodiment, wherein setting the isolation packer includes setting a plurality of isolation packers as a group. 
     Embodiment 22. A method of forming a multi-zone single trip open hole completion comprising: running a multi-zone single trip open hole completion assembly including an anchor and an isolation packer into an open hole well bore to a selected depth; flowing fluid through a bottom zone assembly (BZA) of the completion assembly during run in; setting the anchor with an anchor setting assembly; blocking the fluid flowing through the BZA; and setting the isolation packer by applying pressure to the completion assembly. 
     Embodiment 23. The method according to any prior embodiment, wherein setting the anchor includes operating a flow control system to increase pressure at the anchor setting assembly. 
     Embodiment 24. The method according to any prior embodiment, wherein operating the flow control system includes dropping an object onto an object seat. 
     Embodiment 25. The method according to any prior embodiment, wherein setting the isolation packer includes bypassing the flow control system. 
     Embodiment 26. The method according to any prior embodiment, wherein blocking the fluid flow includes picking up a closing tool to close an isolation valve. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. 
     The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” can include a range of ±8% or 5%, or 2% of a given value. 
     The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers, sands, proppants, etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, gravel packing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. 
     While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.