IP Library Granted Patent US 11,401,780
Granted Patent B2
US 11,401,780 · App. 16/616,559 · Granted Aug 2, 2022

Electronic flow control node to aid gravel pack and eliminate wash pipe

Inventors: Michael Linley Fripp (Carrollton, TX); Stephen Michael Greci (Little Elm, TX)
Assignee: Halliburton Energy Services, Inc.
E21B34/066E21B41/0085E21B43/04E21B43/08E21B47/12
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Quick Facts
Patent No.
US 11,401,780
App. No.
16/616,559
Granted
Aug 2, 2022
Kind
B2
Abstract

A completion assembly to aid in gravel packing a wellbore which assembly includes a plurality of interconnected sand screen assemblies, each sand screen assembly having a wireless adjustable electronic flow control node disposed along the sand screen base pipe to control flow of a gravel packing slurry from the base pipe into the wellbore annulus. Each electronic flow control node includes a valve that can be adjusted by an electric actuator powered by a power harvesting mechanism disposed in a flow path of the completion assembly. A wireless transmitter receives a control signal to control the electric actuator. The control signal may be transmitted sequentially from a distal most sand screen assembly to a proximal sand screen assembly in order to sequentially build the gravel pack.

Claims (56)

1. A method for gravel packing a wellbore annulus comprising:

positioning a completion assembly adjacent a production zone in a wellbore;

pumping a gravel pack slurry down a tubing string to the completion assembly;

actuating a first electronic flow control node carried by the completion assembly to open a valve in the electronic flow control node;

directing slurry flow from the completion assembly into the wellbore annulus around a sand screen of the completion assembly;

detecting an environmental condition adjacent the first electronic flow control node, the environmental condition indicative of a desired degree of completion of a gravel pack around the sand screen; and

actuating, in response to detecting the environmental condition, a second electronic flow control node carried by the completion assembly to open a valve in the second electronic flow control node.

2. The method of claim 1 , wherein pumping comprises pumping a gravel pack slurry down a tubing string to the completion assembly having a plurality of sand screen assemblies with interconnected shunt tubes; and

wherein directing comprises directing slurry flow through the electronic flow control node from a first sand screen assembly to a second sand screen assembly via the interconnected shunt tubes.

3. The method of claim 1 , further comprising transmitting a first signal to actuate the first electronic flow control node carried by the completion assembly to open the valve in the first electronic flow control node;

pumping a working fluid down a tubing string to the completion assembly, the completion assembly having a plurality of sand screen assemblies;

utilizing the first electronic flow control node to inject the working fluid into wellbore by directing working fluid flow through the first electronic flow control node to the wellbore annulus;

transmitting a second signal to actuate the second electronic flow control node carried by the completion assembly to open the valve in the second electronic flow control node; and

utilizing the second electronic flow control node to control flow of formation fluids through a sand screen and into a tubing string.

4. The method of claim 1 , wherein actuating the first electronic control node comprises transmitting a wireless signal to the first electronic flow control node and utilizing the wireless signal to drive the first electronic flow control node from a closed position, whereby flow through the electronic flow control node is blocked to an open position, whereby flow passes through the first electronic flow control node.

5. The method of claim 1 , further comprising, receiving a signal that the gravel pack around the sand screen with the actuated first electronic flow control node has reached the desired degree of completion; actuating the second electronic flow control node in response to receiving the signal.

6. A method for gravel packing a wellbore annulus comprising:

positioning a string of successive, fluidically interconnected sand screen assemblies adjacent a production zone in a wellbore, each sand screen assembly carrying an electronic flow control node with a valve in a closed position;

actuating a first electronic flow control node of a first sand screen assembly positioned at the distal most end of the string to open a valve in the actuated electronic flow control node;

pumping a gravel pack slurry down a tubing string;

directing slurry flow into the wellbore annulus in order to form a gravel pack around the first sand screen assembly;

flowing fluid through the open valve of the actuated first electronic flow control node;

determining that the gravel pack around the first sand screen assembly has reached a desired degree of completion; and

actuating, in response to determining that the gravel pack around the first sand screen assembly has reached the desired degree of completion, a second electronic flow control node of a second sand screen assembly interconnected above the first sand screen assembly.

7. The method of claim 6 , wherein actuating the first electronic control node comprises transmitting a wireless signal to the first electronic flow control node and utilizing the wireless signal to drive the first electronic flow control node from a closed position, whereby flow through the electronic flow control node is blocked to an open position, whereby flow passes through the electronic flow control node.

8. The method of claim 6 , further comprising, receiving a signal that the gravel pack around the first sand screen assembly with the actuated electronic flow control node has reached the desired degree of completion; and actuating the second electronic flow control node in response to receiving the signal in order to gravel pack around the second sand screen assembly.

9. The method of claim 8 , wherein the steps of actuating, pumping and directing are repeated successively from the distal most sand screen assembly to the proximal most sand screen assembly in the string.

10. The method of claim 9 , further comprising directing the slurry flow from an electronic flow control node into a shunt tube and deploying the slurry into the annulus around the sand screen utilizing the shunt tube.

11. The method of claim 9 , wherein, each of the electronic flow control node valves of the successive sand screen assemblies remains open after completion of the gravel packing around the respective sand screen assemblies.

12. A method for gravel packing a wellbore annulus comprising:

positioning a completion assembly adjacent a production zone in a wellbore;

pumping a gravel pack slurry down a tubing string to the completion assembly;

actuating an electronic flow control node carried by the completion assembly to open a valve in the electronic flow control node; and

directing slurry flow through the electronic flow control node from the completion assembly into the wellbore annulus around a sand screen of the completion assembly,

wherein actuating the electronic control node comprises transmitting a wireless signal to the electronic flow control node and utilizing the wireless signal to drive the electronic flow control node from a closed position, whereby slurry flow through the electronic flow control node is blocked to an open position, whereby slurry flow passes through the electronic flow control node.

13. The method of claim 12 , wherein pumping comprises pumping a gravel pack slurry down a tubing string to the completion assembly having a plurality of sand screen assemblies with interconnected shunt tubes; and

wherein directing comprises directing slurry flow through the electronic flow control node from a first sand screen assembly to a second sand screen assembly via the interconnected shunt tubes.

14. The method of claim 12 , further comprising transmitting a first signal to actuate a first electronic flow control node carried by the completion assembly to open the valve in the first electronic flow control node;

pumping a working fluid down a tubing string to the completion assembly, the completion assembly having a plurality of sand screen assemblies;

utilizing the first electronic flow control node to inject the working fluid into wellbore by directing working fluid flow through the first electronic flow control node to the wellbore annulus;

transmitting a second signal to actuate a second electronic flow control node carried by the completion assembly to open a valve in the second electronic flow control node; and

utilizing the second electronic flow control node to control flow of formation fluids through a sand screen and into a tubing string.

15. The method of claim 12 , further comprising, receiving a signal that the gravel pack around the sand screen with the actuated electronic flow control node has reached a desired degree of completion; actuating an electronic flow control node of a sand screen positioned upstream of the gravel packed sand screen; pumping a gravel pack slurry down a tubing string to the actuated electronic flow control node of the upstream screen assembly; and directing slurry flow through the open valve of the actuated electronic flow control node of the upstream screen assembly from the upstream screen assembly into the wellbore annulus in order to gravel pack around the upstream screen assembly.

16. A method for gravel packing a wellbore annulus comprising:

positioning a string of successive, fluidically interconnected sand screen assemblies adjacent a production zone in a wellbore, each sand screen assembly carrying an electronic flow control node with a valve in a closed position;

actuating the electronic flow control node of the sand screen assembly positioned at the distal most end of the string to open a valve in the actuated electronic flow control node;

pumping a gravel pack slurry down a tubing string to the actuated electronic flow control node;

directing slurry flow through the open valve of the actuated electronic flow control node from the sand screen assembly into the wellbore annulus in order to form a gravel pack around the sand screen assembly;

receiving a signal that the gravel pack around the sand screen assembly with the actuated electronic flow control node has reached a desired degree of completion;

actuating an electronic flow control node of a sand screen assembly positioned upstream of the gravel packed sand screen assembly;

pumping a gravel pack slurry down a tubing string to the actuated electronic flow control node of the upstream sand screen assembly; and

directing slurry flow through the open valve of the actuated electronic flow control node of the upstream sand screen assembly from the upstream sand screen assembly into the wellbore annulus in order to gravel pack around the upstream sand screen assembly.

17. The method of claim 16 , wherein actuating the electronic control node comprises transmitting a wireless signal to the electronic flow control node and utilizing the wireless signal to drive the electronic flow control node from a closed position, whereby slurry flow through the electronic flow control node is blocked to an open position, whereby slurry flow passes through the electronic flow control node.

18. The method of claim 16 , wherein the steps of actuating, pumping and directing are repeated successively from the distal most sand screen assembly to the proximal most sand screen assembly in the string.

19. The method of claim 18 , further comprising directing the slurry flow from an electronic flow control node into a shunt tube and deploying the slurry into the annulus around the sand screen utilizing the shunt tube.

20. The method of claim 18 , wherein, each of the electronic flow control node valves of the successive sand screen assemblies remains open after completion of the gravel packing around the respective sand screen assemblies.

Continuity (2)
Provisional Application 62700787 · Jul 19, 2018
Related Publication 20210332668A1 · Oct 28, 2021
Cited By (1)
US 12,281,544