Patent Abstract:
A completion assembly for operation in a subterranean well having multiple production zones. The completion assembly includes a lower completion assembly operably positionable in the well. The lower completion assembly includes first and second zonal isolation subassemblies. An upper completion assembly is operably positionable at least partially within the lower completion assembly to establish fluid communication between first and second fluid flow control modules, respectively, with the first and second zonal isolation subassemblies. A first communication medium having a connection between the upper and lower completion assemblies extends through the first and second zonal isolation subassemblies. A second communication medium is operably associated with the first and second fluid flow control modules. Data obtained by monitoring fluid from the production zones is carried by the first and second communication media and is used to control production through the first and second fluid flow control modules.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit under 35 U.S.C. §119 of the filing date of International Application No. PCT/US2012/057231, filed Sep. 26, 2012. The entire disclosure of this prior application is incorporated herein by this reference. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    This invention relates, in general, to equipment utilized and operations performed in conjunction with a subterranean well and, in particular, to a single trip, multi zone completion assembly having smart well capabilities and methods for use thereof. 
       BACKGROUND OF THE INVENTION 
       [0003]    Without limiting the scope of the present invention, its background is described with reference to providing communication and sensing during a production operation within a subterranean wellbore environment, as an example. It is well known in the subterranean well completion and production arts that downhole sensors can be used to monitor a variety of parameters in the wellbore environment. For example, during production operations, it may be desirable to monitor a variety of downhole parameters such as temperatures, pressures, pH, flowrates and the like in a variety of downhole locations. Transmission of this information to the surface may then allow the operator to modify and optimize the production operations. One way to transmit this information to the surface is using energy conductors such as electrical wires, optical fibers or the like. 
         [0004]    In addition or as an alternative to operating as an energy conductor, optical fibers may serve as a sensor. For example, an optical fiber may be used to obtain distributed measurements representing a parameter along the entire length of the fiber. Specifically, optical fibers have been used for distributed downhole temperature sensing, which provides a more complete temperature profile as compared to discrete temperature sensors. In operation, once an optical fiber is installed in the well, a pulse of laser light is sent along the fiber. As the light travels down the fiber, portions of the light are backscattered to the surface due to the optical properties of the fiber. The backscattered light has a slightly shifted frequency such that it provides information that is used to determine the temperature at the point in the fiber where the backscatter originated. As the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature profile information for the entire length of the fiber. 
         [0005]    Use of an optical fiber for distributed downhole temperature sensing may be highly beneficial during production operations. For example, a distributed temperature profile may be used in determining the location of water or gas influx. Likewise, a distributed temperature profile may be used in determining the location of a failed gravel pack. It has been found, however, that installation of a completion including downhole sensors and energy conductors in a multi zone well requires numerous trips into and out of the well. In addition, it has been found, that even after the sensors and energy conductors have been installed and are providing information relative to production, well intervention may be required to modify or optimize the production operations. 
         [0006]    Therefore, a need has arisen for an improved completion assembly that is operable to monitor a variety of downhole parameters in a variety of downhole locations. A need has also arisen for such an improved completion assembly that does not require numerous trips into and out of the well for multi zone installations. Further, a need has arisen for such an improved completion assembly that does not require well intervention to modify or optimize the production operations following receipt of information from the downhole sensors. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention disclosed herein is directed to a single trip, multi zone completion assembly having smart well capabilities and methods for use thereof. The completion assembly of the present invention is operable to monitor a variety of downhole parameters in a variety of downhole locations. In addition, the completion assembly of the present invention does not require numerous trips into and out of the well for multi zone installations. Further, the completion assembly of the present invention does not require well intervention to modify or optimize the production operations following receipt of information from the downhole sensors. 
         [0008]    In one aspect, the present invention is directed to a completion assembly for operation in a subterranean well having first and second production zones. The completion assembly includes a lower completion assembly that is operably positionable in the well. The lower completion assembly includes first and second zonal isolation subassemblies. An upper completion assembly is operably positionable at least partially within the lower completion assembly to establish fluid communication between first and second fluid flow control modules of the upper completion assembly, respectively, with the first and second zonal isolation subassemblies. A first communication medium having a connection between the upper and lower completion assemblies extends through the first and second zonal isolation subassemblies. A second communication medium is operably associated with the first and second fluid flow control modules. In operation, production from the first production zone is controlled by operating the first fluid flow control module responsive to data obtained by monitoring at least one fluid parameter of fluid from the first production zone (1) exterior of the first zonal isolation subassembly, (2) between the first zonal isolation subassembly and the first fluid flow control module and (3) interior of the first fluid flow control module. In addition, production from the second production zone is controlled by operating the second fluid flow control module responsive to data obtained by monitoring at least one fluid parameter of fluid from the second production zone (1) exterior of the second zonal isolation subassembly, (2) between the second zonal isolation subassembly and the second fluid flow control module and (3) interior of the second fluid flow control module. 
         [0009]    In one embodiment, the first and second zonal isolation subassemblies each include a sand control screen and a production sleeve. In some embodiments, the first and second fluid flow control modules each include a control assembly and a valve assembly. In certain embodiments, the first communication medium may be a distributed temperature sensor. In one embodiment, the upper completion assembly is retrievable from the lower completion assembly. In another embodiments, the upper completion assembly is installed within the well in a single trip. In further embodiments, the lower completion assembly is installed within the well in a single trip. 
         [0010]    In one embodiment, the first communication medium carries data obtained from monitoring the at least one fluid parameter of fluid from the first production zone exterior of the first zonal isolation subassembly and data obtained from monitoring the at least one fluid parameter of fluid from the second production zone exterior of the second zonal isolation subassembly. In another embodiment, the second communication medium carries data obtained from monitoring the at least one fluid parameter of fluid from the first production zone between the first zonal isolation subassembly and the first fluid flow control module and data obtained from monitoring the at least one fluid parameter of fluid from the second production zone between the second zonal isolation subassembly and the second fluid flow control module. In a further embodiment, the second communication medium carries data obtained from monitoring the at least one fluid parameter of fluid from the first production zone interior of the first fluid flow control module and data obtained from monitoring the at least one fluid parameter of fluid from the second production zone interior of the second fluid flow control module. 
         [0011]    In another aspect, the present invention is directed to a method for completing a subterranean well. The method includes positioning a lower completion assembly in the well, the lower completion assembly including first and second zonal isolation subassemblies with a lower portion of a first communication medium extending therethrough and coupled to a lower connector; engaging the lower completion assembly with an upper completion assembly to establish fluid communication between first and second fluid flow control modules of the upper completion assembly, respectively, with the first and second zonal isolation subassemblies, the upper completion assembly including a second communication medium operably associated with the first and second fluid flow control modules and an upper portion of the first communication medium coupled to an upper connector; and operatively connecting the upper and lower connectors to enable communication between the upper and lower portions of the first communication media. 
         [0012]    The method may also include setting a first packer of the upper completion assembly uphole of the lower completion assembly; unlocking an expansion joint of the upper completion assembly uphole of the first packer; setting a second packer of the upper completion assembly uphole of the expansion joint; anchoring the upper completion assembly within the lower completion assembly; engaging seal assemblies of the upper completion assembly with seal bores of the lower completion assembly to isolate the fluid communication between the first fluid flow control module and the first zonal isolation subassembly and to isolate the fluid communication between the second fluid flow control module and the second zonal isolation subassembly; controlling production through the first zonal isolation subassembly by operating an interval control valve of the first fluid flow control module and controlling production through the second zonal isolation subassembly by operating an interval control valve of the second fluid flow control module; monitoring at least one fluid parameter exterior of the first zonal isolation subassembly via the first communication medium, monitoring the at least one fluid parameter between the first zonal isolation subassembly and the first fluid flow control module via the second communication medium and monitoring the at least one fluid parameter interior of the first fluid flow control module via the second communication medium; monitoring the at least one fluid parameter exterior of the second zonal isolation subassembly via the first communication medium, monitoring the at least one fluid parameter between the second zonal isolation subassembly and the second fluid flow control module via the second communication medium and monitoring the at least one fluid parameter interior of the second fluid flow control module via the second communication medium; and/or operating the first communication medium as a distributed temperature sensor. 
         [0013]    In another aspect, the present invention is directed to a method of operating a completion assembly during production from a subterranean well. The method includes providing an upper completion assembly having first and second fluid flow control modules positioned in a lower completion assembly having first and second zonal isolation subassemblies that are, respectively, in fluid communication with the first and second fluid flow control modules and first and second production zones; providing a first communication medium having a connection between the upper and lower completion assemblies and extending through the first and second zonal isolation subassemblies; providing a second communication medium operably associated with the first and second fluid flow control modules; controlling production from the first production zone by operating the first fluid flow control module responsive to data obtained by monitoring at least one fluid parameter of fluid from the first production zone (1) exterior of the first zonal isolation subassembly, (2) between the first zonal isolation subassembly and the first fluid flow control module and (3) interior of the first fluid flow control module; and controlling production from the second production zone by operating the second fluid flow control module responsive to data obtained by monitoring at least one fluid parameter of fluid from the second production zone (1) exterior of the second zonal isolation subassembly, (2) between the second zonal isolation subassembly and the second fluid flow control module and (3) interior of the second fluid flow control module. 
         [0014]    The method may also include operating a first valve assembly to control production from the first production zone and operating a second valve assembly to control production from the second production zone; operating a first interval control valve to control production from the first production zone and operating a second interval control valve to control production from the second production zone; monitoring the at least one fluid parameter of fluid from the first production zone exterior of the first zonal isolation subassembly and monitoring the at least one fluid parameter of fluid from the second production zone exterior of the second zonal isolation subassembly via the first communication medium; operating the first communication medium as a distributed temperature sensor; monitoring the at least one fluid parameter of fluid from the first production zone between the first zonal isolation subassembly and the first fluid flow control module and monitoring the at least one fluid parameter of fluid from the second production zone between the second zonal isolation subassembly and the second fluid flow control module via the second communication medium; and/or monitoring the at least one fluid parameter of fluid from the first production zone interior of the first fluid flow control module and monitoring the at least one fluid parameter of fluid from the second production zone interior of the second fluid flow control module via the second communication medium. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which: 
           [0016]      FIG. 1  is a schematic illustration of an offshore oil and gas platform installing an upper completion assembly into a well having a lower completion assembly disposed therein according to an embodiment of the present invention; and 
           [0017]      FIGS. 2A-2H  are cross sectional views of consecutive axial sections of a single trip, multi zone completion assembly including an upper completion assembly installed within a lower completion assembly during a production operation according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention. 
         [0019]    Referring initially to  FIG. 1 , an upper completion assembly is being installed in a well having a lower completion assembly disposed therein from an offshore oil or gas platform that is schematically illustrated and generally designated  10 . A semi-submersible platform  12  is centered over submerged oil and gas formation  14  located below sea floor  16 . A subsea conduit  18  extends from deck  20  of platform  12  to wellhead installation  22 , including blowout preventers  24 . Platform  12  has a hoisting apparatus  26 , a derrick  28 , a travel block  30 , a hook  32  and a swivel  34  for raising and lowering pipe strings, such as a substantially tubular, axially extending tubing string  36 . 
         [0020]    A wellbore  38  extends through the various earth strata including formation  14  and has a casing string  40  cemented therein. Disposed in a substantially horizontal portion of wellbore  38  is a lower completion assembly  42  that includes various tools such as an orientation and alignment subassembly  44  including a downhole wet mate connector, packer  46 , sand control screen assembly  48 , packer  50 , sand control screen assembly  52 , packer  54 , sand control screen assembly  56  and packer  58 . As described below, packer  46 , sand control screen assembly  48  and packer  50  may be referred to as a zonal isolation subassembly associated with zone  60 . Likewise, packer  50 , sand control screen assembly  52  and packer  54  may be referred to as a zonal isolation subassembly associated with zone  62  and packer  54 , sand control screen assembly  56  and packer  58  may be referred to as a zonal isolation subassembly associated with zone  64 . Extending downhole from orientation and alignment subassembly  44  are one or more energy conductors  66  that pass through packers  46 ,  50 ,  54  and are operably associated with sensors position on sand control screen assemblies  48 ,  52 ,  56  or within the gravel packs surrounding sand control screen assemblies  48 ,  52 ,  56 . Energy conductors  66  may be optical, electrical, hydraulic or the like and may be disposed within a flatpack control umbilical having, for example, one or more hydraulic conductor lines, one or more electrical conductor lines and one or more fiber optic conductor lines that is suitably attached to the exterior of lower completion assembly  42 . Energy conductors  66  may operate as communication media to transmit power, data and the like between the downhole sensors, downhole components and surface equipment. In certain embodiments, one or more of the energy conductors  66  may operate as a downhole sensor. 
         [0021]    For example, if optical fibers are used as one or more of the energy conductors  66 , the optical fibers may be used to obtain distributed measurements representing a parameter along the entire length of the fiber such as distributed temperature or pressure sensing. In this embodiment, a pulse of laser light from the surface is sent along the fiber and portions of the light are backscattered to the surface due to the optical properties of the fiber. The slightly shifted frequency of the backscattered light provides information that is used to determine the temperature or pressure at the point in the fiber where the backscatter originated. In addition, as the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature or pressure profile information for the entire length of the fiber. 
         [0022]    Disposed in wellbore  38  at the lower end of tubing string  36  is an upper completion assembly  68  that includes various tools such as packer  70 , expansion joint  72 , packer  74 , fluid flow control module  76  and anchor assembly  78  including downhole wet mate connector  80 . Extending uphole of connector  80  are one or more energy conductors  82  that pass through packers  70 ,  74  and extend to the surface in the annulus between tubing string  36  and wellbore  38 . Energy conductors  82  are preferably disposed within a flatpack control umbilical as described above that is suitable coupled to tubing string  36 . Energy conductors  82  may be optical, electrical, hydraulic or the like and are preferably of the same type as energy conductors  66  such that energy may be transmitted therebetween following a wet mate connection process between energy conductors  82  and energy conductors  66 . Upper completion assembly  68  also includes one or more energy conductors  84  that pass through packers  70 ,  74  and extend to the surface in the annulus between tubing string  36  and wellbore  38 . Energy conductors  84  are preferably disposed within a flatpack control umbilical that is suitable coupled to tubing string  36 . Energy conductors  84  may be optical, electrical, hydraulic or the like and may operate as communication media to transmit power, data and the like between sensors associated with upper completion assembly  68 , downhole components of upper completion assembly  68  and surface equipment. In certain embodiments, one or more of the energy conductors  84  may operate as a downhole sensor such as a distributed temperature or pressure sensor. 
         [0023]    Even though  FIG. 1  depicts a horizontal wellbore, it should be understood by those skilled in the art that the apparatus according to the present invention is equally well suited for use in wellbores having other orientations including vertical wellbores, slanted wellbores, multilateral wellbores or the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, uphole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the uphole direction being toward the surface of the well, the downhole direction being toward the toe of the well. Also, even though  FIG. 1  depicts an offshore operation, it should be understood by those skilled in the art that the apparatus according to the present invention is equally well suited for use in onshore operations. Further, even though  FIG. 1  depicts a cased hole completion, it should be understood by those skilled in the art that the apparatus according to the present invention is equally well suited for use in open hole completions. 
         [0024]    Referring now to  FIGS. 2A-2H , therein is schematically depicted successive axial sections of the completion assembly of the present invention including a lower completion assembly  100  and an upper completion assembly  200 . As described above, prior to installing upper completion assembly  200 , lower completion assembly  100  is positioned in the well. In the illustrated embodiment, the well includes casing  40  that has been perforated in three zones  60 ,  62 ,  64 . Lower completion assembly  100  will now be described from its uphole end to its downhole end. As best seen in  FIG. 2B , lower completion assembly  100  includes an orientation and alignment subassembly  102  that is operable to receive and rotationally align upper completion assembly  200  within lower completion assembly  100 . Orientation and alignment subassembly  102  includes one or more downhole wet mate connectors  104  that are operable to connect the various energy conductors disposed within a plurality of flatpack control umbilicals  106  (two shown) with a mating connector of upper completion assembly  200 . Umbilicals  106  preferably contained energy conductors such as one or more hydraulic conductor lines, one or more electrical conductor lines and one or more fiber optic conductor lines. Umbilicals  106  are suitably attached to the exterior of lower completion assembly  100 . 
         [0025]    As best seen in  FIG. 2C , downhole of orientation and alignment subassembly  102 , lower completion assembly  100  includes a ported subassembly  108  having one or more fluid ports  110  for allowing fluid communication between the interior and the exterior of lower completion assembly  100 . Lower completion assembly  100  includes a packer assembly  112  having one or more elements  114  for establishing a sealing and gripping relationship with casing  40 . As best seen in  FIG. 2D , downhole of packer assembly  112 , lower completion assembly  100  includes a sand control screen assembly  116 . In the illustrated embodiment, sand control screen assembly  116  includes two filter media  118 ,  120 , a production sleeve  122  and a frac sleeve  124 . Production sleeve  122  and frac sleeve  124  may be operated mechanically, electrically, hydraulically or the like via local or remote operations to selectively allow or disallow fluid flow therethrough. Also, as illustrated, sand control screen assembly  116  has a plurality of sensors  126  that are operably associated with one or more of the energy conductors of umbilicals  106 . Sensors  126  may be of any suitable type for obtaining downhole information such as temperature, pressure, pH, flowrate or the like. Downhole of sand control screen assembly  116 , lower completion assembly  100  includes a seal bore subassembly  128  operable to provide an internal sealing surface. Downhole of seal bore subassembly  128 , lower completion assembly  100  includes a packer assembly  130  having one or more elements  132  for establishing a sealing and gripping relationship with casing  40 . Together, packer assembly  112 , sand control screen assembly  116  and packer assembly  130  may be referred to as a zonal isolation subassembly that is associated with zone  60 , which is depicted as being gravel packed. 
         [0026]    As best seen in  FIG. 2E , lower completion assembly  100  includes a seal bore subassembly  134  operable to provide an internal sealing surface. As best seen in  FIG. 2F , downhole of seal bore subassembly  134 , lower completion assembly  100  includes a sand control screen assembly  136 . In the illustrated embodiment, sand control screen assembly  136  includes two filter media  138 ,  140 , a production sleeve  142  and a frac sleeve  144 . Production sleeve  142  and frac sleeve  144  may be operated mechanically, electrically, hydraulically or the like via local or remote operations to selectively allow or disallow fluid flow therethrough. Also, as illustrated, sand control screen assembly  136  has a plurality of sensors  146  that are operably associated with one or more of the energy conductors of umbilicals  106 . Downhole of sand control screen assembly  136 , lower completion assembly  100  includes a seal bore subassembly  148  operable to provide an internal sealing surface. Downhole of seal bore subassembly  148 , lower completion assembly  100  includes a packer assembly  150  having one or more elements  152  for establishing a sealing and gripping relationship with casing  40 . Together, packer assembly  130 , sand control screen assembly  136  and packer assembly  150  may be referred to as a zonal isolation subassembly that is associated with zone  62 , which is depicted as being gravel packed. 
         [0027]    As best seen in  FIG. 2G , lower completion assembly  100  includes a seal bore subassembly  154  operable to provide an internal sealing surface. As best seen in  FIG. 2H , downhole of seal bore subassembly  154 , lower completion assembly  100  includes a sand control screen assembly  156 . In the illustrated embodiment, sand control screen assembly  156  includes two filter media  158 ,  160 , a production sleeve  162  and a frac sleeve  164 . Production sleeve  162  and frac sleeve  164  may be operated mechanically, electrically, hydraulically or the like via local or remote operations to selectively allow or disallow fluid flow therethrough. Also, as illustrated, sand control screen assembly  156  has a plurality of sensors  166  that are operably associated with one or more of the energy conductors of umbilicals  106 . Downhole of sand control screen assembly  156 , lower completion assembly  100  includes a seal bore subassembly  168  operable to provide an internal sealing surface. Downhole of seal bore subassembly  168 , lower completion assembly  100  includes a packer assembly  170  having one or more elements  172  for establishing a sealing and gripping relationship with casing  40 . Together, packer assembly  150 , sand control screen assembly  156  and packer assembly  170  may be referred to as a zonal isolation subassembly that is associated with zone  64 , which is depicted as being gravel packed. 
         [0028]    Upper completion assembly  200  will now be described from its uphole end to its downhole end. As best seen in  FIG. 2A , upper completion assembly  200  includes a packer assembly  202  having one or more elements  204  for establishing a sealing and gripping relationship with casing  40 . Downhole of packer assembly  202 , upper completion assembly  200  includes an expansion joint  206 , depicted in its fully contracted configuration, that is operable to extend or contract the length of upper completion assembly  200  as described below. Downhole of expansion joint  206 , upper completion assembly  200  includes a packer assembly  208  having one or more elements  210  for establishing a sealing and gripping relationship with casing  40 . As best seen in  FIG. 2B , upper completion assembly  200  includes a fluid flow control module  212 . In the illustrated embodiment, fluid flow control module  212  may be a SCRAMS module from Halliburton that provides for surface controlled reservoir analysis and management in a fully integrated control and data acquisition system. Fluid flow control module  212  includes a plurality of internal sensors  214  and a plurality of external sensors  216  to provide, for example, real-time pressure and temperature data. In addition, fluid flow control module  212  includes an infinitely variable interval control valve  218  which is preferably actuated by hydraulic power routed to an interval control valve piston via solenoid valves (not pictured). Power and communication are provided to fluid flow control module  212  by energy conductors extending from the surface and disposed within a flatpack control umbilical  220  containing, for example, one or more hydraulic conductor lines, one or more electrical conductor lines and one or more fiber optic conductor lines. 
         [0029]    Upper completion assembly  200  includes an anchor assembly  222  that is operable to be received in and oriented by orientation and alignment subassembly  102  of lower completion assembly  100 . Anchor assembly  222  includes wet mate connectors  224  that are operable to connect the various energy conductors disposed within a plurality of flatpack control umbilicals  226  (two shown) with wet mate connectors  104  of lower completion assembly  100 . Umbilicals  226  are suitably attached to the exterior of upper completion assembly  200 . Upper completion assembly  200  has a tubing string  228  that extends into lower completion assembly  100 . Umbilical  220  also extends into lower completion assembly  100  and is suitably attached to the exterior of tubing string  228 . As best seen in  FIG. 2D , tubing string  228  includes a seal assembly  230  having one or more elements  232  for establishing a sealing relationship with the internal sealing surface of seal bore subassembly  128 . As best seen in  FIG. 2E , tubing string  228  also includes a seal assembly  234  having one or more elements  236  for establishing a sealing relationship with the internal sealing surface of seal bore subassembly  134 . Downhole thereof, tubing string  228  includes a fluid flow control module  238  such as the SCRAMS module from Halliburton as described above. Fluid flow control module  238  includes a plurality of internal sensors  240  and a plurality of external sensors  242  to provide, for example, real-time pressure and temperature data. In addition, fluid flow control module  238  includes an infinitely variable interval control valve  244 . Power and communication are provided to fluid flow control module  238  by energy conductors extending from the surface and disposed within flatpack control umbilical  220 . 
         [0030]    As best seen in  FIG. 2F , tubing string  228  includes a seal assembly  246  having one or more elements  248  for establishing a sealing relationship with the internal sealing surface of seal bore subassembly  148 . As best seen in  FIG. 2G , tubing string  228  also includes a seal assembly  250  having one or more elements  252  for establishing a sealing relationship with the internal sealing surface of seal bore subassembly  154 . Further downhole, tubing string  228  includes a fluid flow control module  254  such as the SCRAMS module from Halliburton as described above. Fluid flow control module  254  includes a plurality of internal sensors  256  and a plurality of external sensors  258  to provide, for example, real-time pressure and temperature data. In addition, fluid flow control module  254  includes an infinitely variable interval control valve  260 . Power and communication are provided to fluid flow control module  254  by energy conductors extending from the surface and disposed within flatpack control umbilical  220 . As best seen in  FIG. 2H , tubing string  228  includes a seal assembly  262  having one or more elements  264  for establishing a sealing relationship with the internal sealing surface of seal bore subassembly  168 . 
         [0031]    As illustrated, packer assembly  208  between upper completion assembly  200  and casing  40 , packer assembly  112  between lower completion assembly  100  and casing  40 , and seal assembly  230  between tubing string  228  and lower completion assembly  100  provide an isolated fluid path between sand control screen assembly  116  and fluid flow control module  212 . Likewise, seal assembly  234  and seal assembly  246  between tubing string  228  and lower completion assembly  100  provide an isolated fluid path between sand control screen assembly  136  and fluid flow control module  238 . Also, seal assembly  250  and seal assembly  262  between tubing string  228  and lower completion assembly  100  provide an isolated fluid path between sand control screen assembly  156  and fluid flow control module  254 . In this configuration, production represented by arrows  300  from zone  60  is controlled by fluid flow control module  212 , production from zone  62  represented by arrows  302  is controlled by fluid flow control module  238  and production from zone  64  represented by arrows  304  is controlled by fluid flow control module  254 . 
         [0032]    The operation of installing upper completion assembly  200  into lower completion assembly  100  will now be described. After lower completion assembly  100  has been deployed in the well, preferably in a single trip, each of the zones  60 ,  62 ,  64  may be sequentially gravel packed. After removal of the gravel pack service tools, lower completion assembly  100  is ready to receive upper completion assembly  200 , which is lowered downhole as a single unit on the end of a tubular string as depicted in  FIG. 1 . Preferably, expansion joint  206  is locked in its fully extended configuration during this portion of the installation operation. The lower end of tubing string  228  now enters lower completion assembly  100  as upper completion assembly  200  is lowered into lower completion assembly  100  until anchor assembly  222  engages orientation and alignment subassembly  102 . At this point, seal assemblies  230 ,  234 ,  246 ,  250 ,  262  should be aligned with seal bore assemblies  128 ,  134 ,  148 ,  154 ,  168 , respectively. In this configuration, seal assembly  234  and seal assembly  246  provide an isolated fluid path between sand control screen assembly  136  and fluid flow control module  238 . Likewise, seal assembly  250  and seal assembly  262  provide an isolated fluid path between sand control screen assembly  156  and fluid flow control module  254 . 
         [0033]    Anchor assembly  222  is now anchored or locked within orientation and alignment subassembly  102  and wet mate connectors  224  of upper completion assembly  200  are coupled to wet mate connectors  104  of lower completion assembly  100  to establish communication between respective energy conductors in umbilicals  226  of upper completion assembly  200  and umbilicals  106  of lower completion assembly  100 . Preferably, the connection of wet mate connectors  224  with wet mate connectors  104  proceeds at a controlled speed in accordance with the teachings of U.S. Pat. No. 8,122,967, the entire contents of which is hereby incorporated by reference. In some embodiments, the connection of wet mate connectors  224  with wet mate connectors  104  may be via inductive coupling. Once the wet mate connections are made and communication via the energy conductors therein is tested and confirmed, packer assembly  208  of upper completion assembly  200  is set to establish a sealing and gripping relationship with casing  40 . In this configuration, packer assembly  208 , packer assembly  112  and seal assembly  230  provide an isolated fluid path between sand control screen assembly  116  and fluid flow control module  212 . 
         [0034]    Once packer assembly  208  is set, expansion joint  206  may be unlocked to allow for telescoping of expansion joint  206 . This feature enables improved space out operations and setting of the wellhead without placing stress on the completion assembly. Once the wellhead is landed, packer assembly  202  of upper completion assembly  200  is set to establish a sealing and gripping relationship with casing  40 . Setting this additional packer assembly  202  above expansion joint  206  provides a redundant seal. In the case of a non sealing expansion joint  206 , packer assembly  202  seals off the annulus to prevent tubing fluid from comingling with annulus production and to prevent fluid from migrating up the annulus. In the case of a sealing expansion joint  206 , packer assembly  202  isolates the tubing string from expansion and compression forces exerted by expansion joint  206 . In some embodiments, expansion joint  206  my be omitted in which case, a logging tool may be used to located the wellhead relative to the landing anchor. 
         [0035]    Production operations using the completion assembly of the present invention will now be described. As described above, once upper completion assembly  200  is installed in lower completion assembly  100 , production from zone  60  is controlled by fluid flow control module  212 , production from zone  62  is controlled by fluid flow control module  238  and production from zone  64  is controlled by fluid flow control module  254 . Specifically, this is achieved by monitoring various fluid parameters, such as temperature and pressure at multiple locations associated with production from each zone. For example, sensors  126  are used to obtain fluid parameter data from exterior and the interior of sand control screen assembly  116 . Alternatively or additionally, distributed fluid parameter data may be obtained via one or more of the energy conductors, such as an optic fiber, located in the gravel pack to the exterior of sand control screen assembly  116 . In either case, the data is transmitted to a surface processor for reporting and analysis via energy conductor in umbilicals  106  of lower completion assembly  100  and umbilicals  226  of upper completion assembly  200 . At the same time, additional fluid parameter data may be obtained by sensors  216  in the annulus between upper completion assembly  100  and casing  40  and by sensors  214  to the interior of upper completion assembly  100 . This data is transmitted to a surface processor for reporting and analysis via energy conductors in umbilical  220  of upper completion assembly  200 . The fluid parameter data associated with production from zone  60  is used to control production from zone  60  by making desired adjustments to the position of infinitely variable interval control valve  218 . For example, monitoring pressures to the exterior of sand control screen assembly  116  via certain sensors  126  as well as to the interior of sand control screen assembly  116  via other sensors  126  or via sensors  214 ,  216 , enables monitoring of the pressure drop through the gravel pack and enables redundant measures to identify and diagnosis equipment problems. Commands for controlling the position of variable interval control valve  218  and receiving feedback from variable interval control valve  218  are sent via energy conductors in umbilical  220  of upper completion assembly  200 . In this manner, fluid production from zone  60  is controlled. 
         [0036]    Regarding zone  62 , sensors  146  are used to obtain fluid parameter data from exterior and the interior of sand control screen assembly  136 . Alternatively or additionally, distributed fluid parameter data may be obtained via one or more of the energy conductors, such as an optic fiber, located in the gravel pack to the exterior of sand control screen assembly  136 . In either case, the data is transmitted to a surface processor for reporting and analysis via energy conductor in umbilicals  106  of lower completion assembly  100  and umbilicals  226  of upper completion assembly  200 . At the same time, additional fluid parameter data may be obtained by sensors  242  in the annulus between upper completion assembly  100  and lower completion assembly  200  and by sensors  240  to the interior of upper completion assembly  100 . This data is transmitted to a surface processor for reporting and analysis via energy conductors in umbilical  220  of upper completion assembly  200 . The fluid parameter data associated with production from zone  62  is used to control production from zone  62  by making desired adjustments to the position of infinitely variable interval control valve  244 . Commands for controlling the position of variable interval control valve  244  and receiving feedback from variable interval control valve  244  are sent via energy conductors in umbilical  220  of upper completion assembly  200 . In this manner, fluid production from zone  62  is controlled. 
         [0037]    Regarding zone  64 , sensors  166  are used to obtain fluid parameter data from exterior and the interior of sand control screen assembly  156 . Alternatively or additionally, distributed fluid parameter data may be obtained via one or more of the energy conductors, such as an optic fiber, located in the gravel pack to the exterior of sand control screen assembly  156 . In either case, the data is transmitted to a surface processor for reporting and analysis via energy conductor in umbilicals  106  of lower completion assembly  100  and umbilicals  226  of upper completion assembly  200 . At the same time, additional fluid parameter data may be obtained by sensors  258  in the annulus between upper completion assembly  100  and lower completion assembly  200  and by sensors  256  to the interior of upper completion assembly  100 . This data is transmitted to a surface processor for reporting and analysis via energy conductors in umbilical  220  of upper completion assembly  200 . The fluid parameter data associated with production from zone  64  is used to control production from zone  64  by making desired adjustments to the position of infinitely variable interval control valve  260 . Commands for controlling the position of variable interval control valve  260  and receiving feedback from variable interval control valve  260  are sent via energy conductors in umbilical  220  of upper completion assembly  200 . In this manner, fluid production from zone  64  is controlled. 
         [0038]    While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.

Technology Classification (CPC): 4