WO2020153864A1

WO2020153864A1 - Single trip completion systems and methods

Info

Publication number: WO2020153864A1
Application number: PCT/RU2019/000037
Authority: WO
Inventors: Krishna TRISAL; Farid AFANDIYEV; Saeed MOLAVI; Ilyana Sergeevna AFANASYEVA
Original assignee: Schlumberger Canada Limited; Schlumberger Technology B.V.; Services Petroliers Schlumberger; Schlumberger Technology Corporation
Priority date: 2019-01-23
Filing date: 2019-01-23
Publication date: 2020-07-30

Abstract

The present disclosure generally relates to systems and methods for completing wells by running an integrated well completion string downhole into a well as an integrated unit in a single trip. In certain embodiments, the integrated well completion string includes a surface- controlled subsurface safety valve (SCSSV), a production packer disposed downhole with respect to the SCSSV, a stand-alone screen disposed downhole with respect to the production packer, and a washdown shoe disposed downhole with respect to the stand-alone screen. In certain embodiments, the stand-alone screen is configured to block fluid flow radially outward from an interior passageway of the integrated well completion string into the annulus between the integrated well completion string and the reservoir while the integrated well completion string is run downhole into the well. Once the integrated well completion string is deployed, and the open hole has been displaced to filter cake breaker fluid, the stand-alone screen then operates as a standard screen, allowing flow in both directions (radially inward and outward) to produce from and/or inject into the reservoir.

Description

SINGLE TRIP COMPLETION SYSTEMS AND METHODS

BACKGROUND

[0001] The present disclosure generally relates to well completions and, more particularly, to systems and methods for deploying open hole stand-alone screen completions in a single trip.

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as an admission of any kind.

[0003] Conventional open hole stand-alone screen completions are deployed using two trips. For example, the first trip is performed to install a lower completion that typically includes, among other components, a washdown shoe, sand screens, a fluid loss control device, a sealbore extension, and a sealbore packer. The lower completion is typically conveyed to a final depth with a running string that is connected to a service tool. Once the lower completion is installed and tested, the workstring (e.g., the running string and the service tool) are retrieved to the surface of the well. Then, the second trip is performed to install an upper completion that typically includes, among other components, a production packer, permanent downhole monitoring equipment, and a surface-controlled subsurface safety valve (SCSSV).

SUMMARY

[0004] A summary of certain embodiments described herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure.

[0005] One embodiment of the present disclosure includes a method includes running an integrated well completion string downhole into a well as an integrated unit. The integrated well completion string includes a surface-controlled subsurface safety valve (SCSSV), a production packer disposed downhole with respect to the SCSSV, a stand-alone screen disposed downhole with respect to the production packer, and a washdown shoe disposed downhole with respect to the stand-alone screen. The method also includes blocking fluid flow radially outward through the stand-alone screen from an interior passageway of the integrated well completion string into an annulus formed between the integrated well completion string and a wellbore of the well while the integrated well completion string is run downhole into the well. The method further includes allowing bi-directional radial fluid flow through the stand-alone screen after the integrated well completion string has been run downhole into the well.

[0006] Another embodiment of the present disclosure includes a well completion system that includes an integrated well completion string configured to be run downhole into a well as an integrated unit to complete the well. The integrated well completion string includes a surface-controlled subsurface safety valve (SCSSV) configured to block uncontrolled fluid flow uphole through an interior passageway of the integrated well completion string. The integrated well completion string also includes a production packer configured to anchor the integrated well completion string within a wellbore of the well. The integrated well completion string further includes a stand-alone screen configured to block fluid flow radially outward from the interior passageway of the integrated well completion string into an annulus formed between the integrated well completion string and the wellbore of the well while the integrated well completion string is run downhole into the well, and to allow bi-directional radial fluid after the integrated well completion string has been run downhole into the well. In addition, the integrated well completion string includes a washdown shoe configured to allow fluid flow from the interior passageway of the integrated well completion string into the annulus, and to block fluid flow from the annulus into the interior passageway of the integrated well completion string.

[0007] Another embodiment of the present disclosure includes a method includes running an integrated well completion string downhole into a well as an integrated unit. The integrated well completion string comprises a surface-controlled subsurface safety valve (SCSSV), a production packer disposed downhole with respect to the SCSSV, a stand-alone screen disposed downhole with respect to the production packer, and a washdown shoe disposed downhole with respect to the stand-alone screen.

[0008] Various refinements of the features noted above may be undertaken in relation to various aspects of the present disclosure. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any of the above-described aspects of the present disclosure alone or in any combination. The brief summary presented above is intended to familiarize the reader with certain aspects and contexts of embodiments of the present disclosure without limitation to the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Various aspects of this disclosure may be better understood upon reading the following detailed description and upon reference to the drawings, in which:

[0010] FIG. 1 is a partial cutaway side view of a well that includes a wellbore that extends through one or more formations that contain a hydrocarbon-based fluid, in accordance with embodiments of the present disclosure;

[0011] FIG. 2 is a partial cutaway side view of a single trip well completion system configured to be run into a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure;

[0012] FIG. 3 is a partial cutaway side view of another example of a single trip well completion system configured to be run into a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure;

[0013] FIG. 4 is a partial cutaway side view of another example of a single trip well completion system configured to be run into a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure;

[0014] FIG. 5 is a partial cutaway side view of another example of a single trip well completion system configured to be run into a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure;

[0015] FIG. 6 is a partial cutaway side view of another example of a single trip well completion system configured to be run into a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure; and [0016] FIG. 7 is a block diagram of a method of installing a single trip well completion system in a wellbore of an open hole well as an integrated unit in a single trip, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

[0017] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0018] When introducing elements of various embodiments of the present disclosure, the articles“a,”“an,” and“the” are intended to mean that there are one or more of the elements. The terms“comprising,”“including,” and“having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to“one embodiment” or“an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0019] As used herein, the terms“connect,”“connection,”“connected,”“in connection with,” and“connecting” are used to mean“in direct connection with” or“in connection with via one or more elements”; and the term“set” is used to mean“one element” or“more than one element.” Further, the terms “couple,” “coupling,” “coupled,” “coupled together,” and

“coupled with” are used to mean“directly coupled together” or“coupled together via one or more elements.” As used herein, the terms“up” and“down,”“uphole” and“downhole”,

“upper” and“lower,”“top” and“bottom,” and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements. Commonly, these terms relate to a reference point as the surface from which drilling operations are initiated as being the top (e.g., uphole or upper) point and the total depth along the drilling axis being the lowest (e.g., downhole or lower) point, whether the well (e.g., wellbore, borehole) is vertical, horizontal or slanted relative to the surface.

[0020] As described above, conventional stand-alone screen completions, such as in open hole wells, are typically deployed using two trips. Prior to installation of lower completion components, the open hole is usually displaced to solids-free fluid, and the casing is usually displaced to filtered brine. The lower completion components are typically run into the wellbore as a string, with a washdown shoe being run first, followed by sand screens, a fluid loss control device, a sealbore packer extension, and a sealbore packer. At some point, usually right before or after the fluid loss control device is made up to the string, the lower completion is set in slips and a false rotary is positioned over the string, at which point an inner string may be run into the wellbore, which usually includes a washpipe string having a stinger at a downhole end, which stabs into the sealbore right above the washdown shoe. A service tool assembly is then usually coupled to the washpipe string. Typically, at this point, the sealbore packer engages threads of the outer string (e.g., the sand screens) while the service tool engages the inner string (e.g., the washpipe). The entire lower completion string is then conveyed to a final depth via drillpipe.

[0021] Then, once the lower completion is positioned at the correct depth, the sealbore packer is usually set using pressure from the surface of the well, and the seal and mechanical integrity of the sealbore packer is tested. Typically, filter cake breaker fluid is then pumped down through the drillpipe and the washpipe, which displaces the solids-free fluid in the open hole, and which facilitates removal of filter cake. However, in certain situations, the filter cake breaker fluid may alternatively be pumped down through the drillpipe and the washpipe prior to setting the sealbore packer. In such situations, the displacement path is down through the drillpipe and the washpipe, then up through the annulus via the washdown shoe. Once the displacement is complete, the workstring (e.g., including the running string and the service tool) is pressured up to set the sealbore packer.

[0022] In either scenario, the service tool is then typically pulled out of the wellbore, leaving the lower completion components (e.g., the washdown shoe, the sand screens, the fluid loss control device, the sealbore packer extension, and the sealbore packer) in place within the wellbore. The washpipe is typically also retrieved as part of the workstring. The fluid loss control device is typically tested once the washpipe is above the fluid loss control device, thereby making sure that the fluid loss control device is still holding fluid column above to prevent losses during the upper completion installation.

[0023] Then, the upper completion installation follows the lower completion deployment. Various components may be included in the upper completion, but often include tubing, a tubing blanking device, a production packer, a surface-controlled subsurface safety valve (SCSSV), and a tubing hanger. Typically, once the tubing hanger is landed, the production packer is set against the tubing blanking device. Then, the tubing integrity is pressure tested followed by an inflow test of the SCSSV. The final step is typically pressure testing the production packer and tubing hanger seals from the backside. Once the well is coupled to a production Christmas tree, the tubing blanking device is often removed or shifted to an open position, either remotely or through tubing intervention, and the fluid loss control device is opened using pressure cycles or mechanical means, depending on the type of fluid loss control device used.

[0024] Embodiments of the present disclosure overcome shortcomings of conventional open hole stand-alone screen completions by utilizing a completion and deployment philosophy that facilitates the installation of stand-alone screens and the completion of wells in a single trip of an integrated well completion string. In particular, as described in greater detail herein, the embodiments of the present disclosure, for example, eliminate the need for running a sealbore packer, sealbore extension, fluid loss control device, internal washpipe string, and an intermediate workstring (e.g., running string and service tool). As such, the embodiments described herein provide cost savings through the single trip installation, which also significantly reduces rig time over the conventional two-trip completion installations described above. In particular, time is saved because there is no requirement to run and retrieve, for example, washpipe and drillpipe strings to convey the stand-alone screens to depth. Furthermore, the embodiments described herein do not require that a fluid loss control device, sealbore extension, and sealbore packer be run into the wellbore. The embodiments described herein also reduce the amount of rental equipment (e.g., a sealbore packer setting tool, internal washpipe including stinger, and other handling equipment) needed for completion of the well.

[0025] FIG. 1 is a partial cutaway side view of a well 10 that includes a wellbore 12 that extends through one or more formations 14 (e.g., reservoirs) that contain a hydrocarbon-based fluid, in accordance with embodiments of the present disclosure. The embodiment illustrated in FIG. 1 depicts the wellbore 12 having a first segment (e.g., a cased hole segment 16) that is cased by a casing 18 and a second segment that is an uncased open hole segment 20. Although illustrated in FIG. 1 as being a vertical uncased open hole segment, in other embodiments, the uncased open hole segment 20 may instead include a lateral segment. In addition, in other embodiments, the wellbore 12 may include more than one lateral uncased open hole segment. Furthermore, various systems, assemblies, techniques, etc. may be applied to land wells, subsea wells, and so forth, which can include one or more vertical segments and/or one or more deviated segments, which may include one or more lateral segments (e.g., one or more substantially horizontal segments).

[0026] The embodiment illustrated in FIG. 1 includes an integrated single trip well completion system 22, which may be installed via appropriate equipment (e.g., rig equipment, and so forth). As illustrated, the single trip well completion system 22 is part of a tubular string 24 with appropriate upper completion equipment, which extends to the surface 26 of the well 10 and hangs from a tubing hanger (not shown) provided at its upper axial end. As described herein, the well 10 may be defined by a central axis 44 along the wellbore 12 from an upper (e.g., uphole) axial end at the surface 26 of the well 10 to a lower (e.g., downhole) axial end, which may be vertical and/or deviated, as described herein. Axial and/or radial coordinates may be used herein to define the position of one or more components of the single trip well completion system 22 along the central axis 44 defined by the wellbore 12.

[0027] The single trip well completion system 22 described herein may be installed as an integrated unit using a single trip into the well 10 (e.g., in a single run without removing any components of the single trip well completion system 22 during the run into the wellbore 12). In other words, as opposed to conventional systems that include upper and lower completions that are separately run into a wellbore in two trips, the embodiments of the single trip well completion system 22 described herein incorporate completion components that are conventionally included in both upper and lower completions in an integrated unit that may be run into the wellbore 12 in a single trip. For example, the single trip well completion system 22 may be considered to include both an upper completion and a lower completion, which are approximately identified in FIG. 1 as an upper section 28 (e.g., or upper portion, upper completion, uphole section, etc.) and a lower section 30 (e.g., or lower portion, lower completion, downhole section, etc.), respectively, of the single trip well completion system 22.

[0028] As illustrated in FIG. 1, the lower section 30 of the single trip well completion system 22 may include a screen assembly 32 (e.g., a stand-alone screen), which extends into the uncased open hole segment 20 of the wellbore 12. However, in other embodiments, the screen assembly 32 may extend inside of the casing 18 if the well 10 is entirely cased (i.e., not open hole). The screen assembly 32 may be located near the lower (e.g., downhole) end of the lower section 30 and communicate well fluid from an annulus 34 that surrounds the screen assembly 32 into an interior passageway 36 of the single trip well completion system 22 (and the tubular string 24).

[0029] In addition, as described in greater detail herein, in certain embodiments, the screen assembly 32 is configured to block fluid flow radially outward from the interior passageway 36 of the single trip well completion system 22 into the annulus 34 while the single trip well completion system 22 is run downhole into the well 10. In other words, depending on whether the single trip well completion system 22 is being run into the well 10 or has already been set to the final depth, the functionality of the screen assembly 32 may change. In particular, while the single trip well completion system 22 is being run downhole into the well 10, by blocking fluid flow radially outward into the open hole, the screen assembly 32 provides washdown functionality by ensuring that the fluid flow pumped down through the single trip well completion system 22 will only enter the open hole after passing through a washdown shoe 40 disposed at the lower (e.g., downhole) end of the single trip well completion system 22, which obviates the need of running washpipe, among other components, in a separate trip, as described in greater detail herein. Rather, the screen assembly 32 acts as a blank joint during deployment of the single trip well completion system 22 (i.e., which enables the washdown functionality), but converts to a normal sand screen assembly for production after deployment of the single trip well completion system 22.

[0030] In certain embodiments, the single trip well completion system 22 may form an annular seal between the exterior of the single trip well completion system 22 and the interior surface of the casing 18 through the setting of a production packer 38, which is part of the lower section 30 and is disposed near the upper (e.g., uphole) end of the lower section 30. Due to this arrangement, produced well fluid is directed to flow through the screen assembly 32, into the single trip well completion system 22 and, thus, into the tubular string 24 to the surface 26 of the well 10. In general, the production packer 38 acts as a mechanical anchoring and pressure isolation device during the life cycle of the well 10. In certain embodiments, the production packer 38 may a hydraulically-set packer. However, in other embodiments, the production packer 38 may be another type of packer that is set by another mechanism. In certain embodiments in which the production packer 38 is a hydraulically-set packer, the production packer 38 may be set using the internal tubing pressure that is conveyed downhole through the interior passageway 36 of the tubular string 24 (and the single trip well completion system 22).

[0031] In certain embodiments, the single trip well completion system 22 may include the washdown shoe 40 at its lower (e.g., downhole) end, which may be configured to seal off the interior passageway 36 of the single trip well completion system 22 at axial locations below the production packer 38. In certain embodiments, the sealing of the interior passageway 36 of the single trip well completion system 22 allows for a build-up or increase in pressure, which may be utilized to set the production packer 38. In general, the washdown shoe 40 has at least three roles: enabling smoother running of the single trip well completion system 22 downhole into the wellbore 12 due to the shape and washdown circulation functionality; acting as a check valve that allows fluid flow from within the interior passageway 36 of the single trip well completion system 22 into the annulus 34 formed between the single trip well completion system 22 and the wellbore 12, while blocking fluid flow in the opposite direction; and helping to ensure that the filter cake breaker fluid is spotted across the entire open hole.

[0032] In certain embodiments, the washdown shoe 40 may contain a ball seat that accepts a ball plug that is deployed (e.g., dropped and/or pumped) from the surface 26 of the well 10. However, other embodiments may utilize other types of valves to create a sealed volume in the interior passageway 36 of the single trip well completion system 22 for the purpose of actuating the production packer 38. For example, in certain embodiments, one or more formation isolation valves may be used to reversibly seal and/or to prevent communication between one portion of the interior passageway 36 of the single trip well completion system 22 and another portion of the interior passageway 36.

[0033] In certain embodiments, as described in greater detail herein, the production packer 38 may be a multiple port packer, which may allow for multiple feedthroughs for control lines and/or communication cables (e.g., electrical cables, optical cables, etc.) to extend in the annulus 34 between portions of the single trip well completion system 22 separated by the production packer 38. In certain embodiments, the production packer 38 may be mechanically set or set via a control line, thereby obviating the need for separate setting components such as a tubing isolation plug below the production packer 38.

[0034] The single trip well completion system 22 described herein may be compatible with various mud systems, may be deployable in deepwater environments, subsea environments and/or terrestrial well systems. In addition, the single trip well completion system 22 described herein may be compatible with various types of completion components. In certain embodiments, the single trip well completion system 22 may provide for water injection or other forms of well operation alternatively or in addition to hydro-carbon production.

[0035] To further illustrate the functionality of the embodiments described herein, FIG. 2 is a partial cutaway side view of a single trip well completion system 22 configured to be run into a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure. As described in greater detail herein, the single trip well completion system 22 is an integrated well completion string configured to be run downhole into the well 10 as an integrated unit to complete the well 10. As illustrated in FIG. 2, in certain embodiments, the single trip well completion system 22 includes a surface- controlled subsurface safety valve (SCSSV) 42 configured to block uncontrolled fluid flow uphole through the interior passageway 36 of the single trip well completion system 22. In addition, in certain embodiments, the single trip well completion system 22 includes the production packer 38 disposed downhole with respect to the SCSSV 42 along the central axis 44 of the wellbore 12. As described herein, the production packer 38 is configured to, among other things, anchor the single trip well completion system 22 within the wellbore 12 of the well 10 (e.g., against the casing 18 of the cased hole segment 16 of the wellbore 12).

[0036] In addition, in certain embodiments, the single trip well completion system 22 includes a stand-alone screen 32 disposed downhole with respect to the production packer 38 along the central axis 44 of the wellbore 12. As described in greater detail herein, the standalone screen 32 is configured to block fluid flow radially outward from the interior passageway 36 of the single trip well completion system 22 into the annulus 34 formed between the single trip well completion system 22 and the uncased open hole segment 20 of the wellbore 12 of the well 10 (while allowing fluid flow radially inward, in the opposite direction) while the single trip well completion system 22 is run downhole into the well 10, and to allow bi-directional radial fluid flow from the annulus 34 into the interior passageway 36 of the single trip well completion system 22 after the single trip well completion system 22 has been run downhole into the well 10. In particular, while the single trip well completion system 22 is being run downhole into the well 10, the stand-alone screen 32 provides washdown functionality, which obviates the need of running washpipe, among other components, in a separate trip. Once the completion has been deployed, and filter cake breaker fluid has been spotted in the open hole, the stand-alone screen 32 no longer needs to have washdown functionality (i.e. the stand-alone screen 32 no longer blocks fluid flow radially outward from the interior passageway 36 of the single trip well completion system 22 to the open hole).

[0037] In addition, in certain embodiments, the single trip well completion system 22 includes the washdown shoe 40 disposed downhole with respect to the stand-alone screen 32 along the central axis 44 of the wellbore 12. As described above, the washdown shoe 40 is configured to allow fluid flow from the interior passageway 36 of the single trip well completion system 22 into the annulus 34, while blocking fluid flow from the annulus 34 into the interior passageway 36 of the single trip well completion system 22. In addition, in certain embodiments, the single trip well completion system 22 optionally includes a tubing blanking device 46 disposed between the production packer 38 and the stand-alone screen 32 (e.g., downhole of the production packer 38 and uphole of the stand-alone screen 32) along the central axis 44 of the wellbore 12. In general, the tubing blanking device 46 may be used for various tasks, such as setting the production packer 38, testing certain tubing components of the single trip well completion system 22, isolation of the formation 14, and so forth. In certain embodiments, the tubing blanking device 46 may either be remotely controlled or using intervention.

[0038] In addition, in certain embodiments, the single trip well completion system 22 optionally includes gas lift mandrels 48 disposed between the SCSSV 42 and the production packer 38 (e.g., downhole of the SCSSV 42 and uphole of the production packer 38) along the central axis 44 of the wellbore 12. In addition, in certain embodiments, the single trip well completion system 22 optionally includes a permanent downhole gauge 50 (e.g., to monitor temperature, pressure, and so forth) disposed between the SCSSV 42 and the production packer 38 (e.g., downhole of the SCSSV 42 and uphole of the production packer 38) along the central axis 44 of the wellbore 12.

[0039] In general, the embodiment of the single trip well completion system 22 illustrated in FIG. 2 includes the cased hole segment 16 of the wellbore 12 displaced to filtered brine and the uncased open hole segment 20 of the wellbore 12 displaced to mud before the single trip well completion system 22 is run into the wellbore 12 as an integrated unit in a single trip. The process of running the single trip well completion system 22 illustrated in FIG. 2 into the wellbore 12 as an integrated unit in a single trip begins with conditioning of the mud in the well 10 to production screen testing (PST) specifications prior to running the stand-alone screen 32 as part of the single trip well completion system 22. Once the mud is conditioned, the single trip well completion system 22 is run into the wellbore 12 as an integrated unit to a target depth. Once the single trip well completion system 22 is installed at the target depth, a tubing hanger (not shown) coupled to an upper (e.g., uphole) end of the single trip well completion system 22 is landed and locked into place within the wellbore 12 (e.g., against the casing 18 of the cased hole segment 16 of the wellbore 12).

[0040] Once the tubing hanger is locked into place within the wellbore 12, the stand-alone screen 32 and the washdown shoe 40 both perform washdown functions to displace fluid in the annulus 34 formed between the single trip well completion system 22 and the uncased open hole segment 20 of the wellbore 12, and to flow filter cake breaker fluid from the interior passageway 36 of the single trip well completion system 22 into the annulus 34. After the filter cake breaker fluid is introduced into the annulus 34, the stand-alone screen 32 no longer functions in a pump down mode (i.e., fluid flow is then allowed to flow radially outward from the interior passageway 36 of the single trip well completion system 22 into the annulus 34) and, as such, the stand-alone screen 32 functions in a normal sand screen mode (i.e., where fluid is allowed to radially flow bi-directionally across the stand-alone screen 32).

[0041] Then, the tubing blanking device 46 is closed, the tubular string 24 of the single trip well completion system 22 is pressured up to set the production packer 38, and an inflow test of the SCSSV 42 is performed. In addition, the production packer 38 and seals of the tubing hanger are annulus tested to ensure integrity of the well 10. Once these testing procedures have been completed, the single trip well completion system 22 may be coupled to a Christmas tree at the surface 26 of the well 10. Then, the tubing blanking device 46 is either removed or cycled to an open position to allow production from the well 10. The well 10 can then be prepared for flowback by creating an underbalance between pressure in the wellbore 12 and pressure of the reservoir 14.

[0042] FIG. 3 is a partial cutaway side view of another example of a single trip well completion system 22 configured to be run into a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure. Again, the single trip well completion system 22 illustrated in FIG. 3 is an integrated well completion string configured to be run downhole into the well 10 as an integrated unit to complete the well 10. The embodiment of the single trip well completion system 22 illustrated in FIG. 3 is substantially similar to the embodiment illustrated in FIG. 2. However, the embodiment illustrated in FIG. 3 includes a circulation sleeve 52 disposed between the production packer 38 and the tubing blanking device 46 (e.g., downhole of the production packer 38 and uphole of the tubing blanking device 46) along the central axis 44 of the wellbore 12. The circulation sleeve 52 acts as a circulation sleeve between the tubular string 24 and the annulus 34 and formation 14. In general, the circulation sleeve 52 is configured to displace fluid in the cased hole segment 16 of the wellbore 12 after installation of the single trip well completion system 22 at a target depth. Although illustrated in FIG. 3 as being disposed below the production packer 38, in other embodiments, the circulation sleeve 52 may instead be disposed above the production packer 38 to help unload the well 10 after the single trip well completion system 22 has been installed. In certain embodiments, the circulation sleeve 52 may either be remotely controlled or deployed using intervention.

[0043] In general, the embodiment of the single trip well completion system 22 illustrated in FIG. 3 includes both the cased hole segment 16 of the wellbore 12 and the uncased open hole segment 20 of the wellbore 12 displaced to mud before the single trip well completion system 22 is run into the wellbore 12 as an integrated unit in a single trip. The process of running the single trip well completion system 22 illustrated in FIG. 3 into the wellbore 12 as an integrated unit in a single trip begins with conditioning of the mud in the well 10 to production screen testing (PST) specifications prior to running the stand-alone screen 32 as part of the single trip well completion system 22. Once the mud is conditioned, the single trip well completion system 22 is run into the wellbore 12 as an integrated unit to a target depth. Once the single trip well completion system 22 is installed at the target depth, a tubing hanger (not shown) coupled to an upper (e.g., uphole) end of the single trip well completion system 22 is landed and locked into place within the wellbore 12 (e.g., against the casing 18 of the cased hole segment 16 of the wellbore 12).

[0044] Once the tubing hanger is locked into place within the wellbore 12, the tubing blanking device 46 is cycled to a closed position, and the circulation sleeve 52 is opened such that filtered completion brine in the cased hole segment 16 of the wellbore 12 is displaced. Then, the circulation sleeve 52 is closed.

[0045] Once the circulation sleeve 52 has been closed, the stand-alone screen 32 and the washdown shoe 40 both perform washdown functions to displace fluid in the annulus 34 formed between the single trip well completion system 22 and the uncased open hole segment 20 of the wellbore 12, and to flow filter cake breaker fluid from the interior passageway 36 of the single trip well completion system 22 into the annulus 34. After the filter cake breaker fluid is introduced into the annulus 34, the stand-alone screen 32 no longer functions in a pump down mode (i.e., fluid flow is then allowed to flow radially outward from the interior passageway 36 of the single trip well completion system 22 into the annulus 34) and, as such, the stand-alone screen 32 functions in a normal sand screen mode (i.e., where fluid is allowed to radially flow bi-directionally across the stand-alone screen 32).

[0046] Then, the tubing blanking device 46 is closed, the tubular string 24 of the single trip well completion system 22 is pressured up to set the production packer 38, and an inflow test of the SCSSV 42 is performed. In addition, the production packer 38 and seals of the tubing hanger are annulus tested to ensure integrity of the well 10. Once these testing procedures have been completed, the single trip well completion system 22 may be coupled to a Christmas tree at the surface 26 of the well 10. Then, the tubing blanking device 46 is either removed or cycled to an open position to allow production from the well 10. The well 10 can then be prepared for flowback by creating an underbalance between pressure in the wellbore 12 and pressure of the reservoir 14.

[0047] Other embodiments of the single trip well completion system 22 may include additional features. For example, FIG. 4 is a partial cutaway side view of another example of a single trip well completion system 22 configured to be run into a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure. Again, the single trip well completion system 22 illustrated in FIG. 4 is an integrated well completion string configured to be run downhole into the well 10 as an integrated unit to complete the well 10. The embodiment of the single trip well completion system 22 illustrated in FIG. 4 is substantially similar to the embodiment illustrated in FIG. 3. However, the embodiment illustrated in FIG. 4 includes a surface-controlled barrier valve 54 instead of the tubing blanking device 46 illustrated in FIGS. 2 and 3. As illustrated in FIG. 4, similar to the tubing blanking device 46, the surface-controlled barrier valve 54 is disposed between the production packer 38 and the stand-alone screen 32 (e.g., downhole of the production packer 38 and uphole of the stand-alone screen 32) along the central axis 44 of the wellbore 12. In certain embodiments, the surface-controlled barrier valve 54 functions as a deepset barrier when, for example, removing a blowout preventer or during any intervention operations performed during the life cycle of the well 10. In addition, in certain embodiments, the surface-controlled barrier valve 54 may also be used to set the production packer 38 hydraulically. [0048] FIG. 5 is a partial cutaway side view of another example of a single trip well completion system 22 configured to be run into a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure. Again, the single trip well completion system 22 illustrated in FIG. 5 is an integrated well completion string configured to be run downhole into the well 10 as an integrated unit to complete the well 10. The embodiment of the single trip well completion system 22 illustrated in FIG. 5 is substantially similar to the embodiment illustrated in FIG. 4. However, the embodiment illustrated in FIG. 5 includes a pressure-activated disconnect joint 56 that may also be run into the wellbore 12 above the stand-alone screen 32. As illustrated in FIG. 5, the pressure-activated disconnect joint 56 is disposed between the surface-controlled barrier valve 54 and the stand-alone screen 32 (e.g., downhole of the surface-controlled barrier valve 54 and uphole of the stand-alone screen 32) along the central axis 44 of the wellbore 12. In situations where the single trip well completion system 22 becomes stuck during deployment, and the tubular string 24 is unable to move up or down, then pressure may be applied to shear the pressure-activated disconnect joint 56 and recover the components of the single trip well completion system 22 above the pressure-activated disconnect joint 56. The remaining components of the single trip well completion system 22, including the stand-alone screen 32, may then be recovered using, for example, a separate string with fishing equipment such as an overshot, spear, and so forth.

[0049] In certain embodiments, the single trip well completion system 22 facilitates the installation of reservoir monitoring and/or flow control tools across the stand-alone screen 32 and the sand face completion. In certain embodiments, the reservoir monitoring and/or flow control tools may include one or more permanent downhole gauges 50, distributed temperature sensors (e.g., fiber optic distributed temperature sensors), distributed acoustic sensors (e.g., for sand detection and seismic surveying), flow meter measurements, and other various monitoring systems.

[0050] FIG. 6 is a partial cutaway side view of another example of a single trip well completion system 22 configured to be run into a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure.

Again, the single trip well completion system 22 illustrated in FIG. 6 is an integrated well completion string configured to be run downhole into the well 10 as an integrated unit to complete the well 10. The embodiment of the single trip well completion system 22 illustrated in FIG. 6 is substantially similar to the embodiment illustrated in FIGS. 4 and 5, which includes a surface-controlled barrier valve 54. However, the embodiment illustrated in FIG. 6 includes sensor cables and/or fiber optic lines 58 (e.g., hydraulic lines, electric lines, and so forth) that facilitate the use of reservoir monitoring and/or flow control tools 60 (e.g., intelligent completion tools) installed across the sand face.

[0051] Furthermore, in certain embodiments, as described herein, the production packer 38 may include bypass ports 62 that enable the sensor cables and/or fiber optic lines 58 to be installed over the entire length of the single trip well completion system 22, without the need for connections and disconnections between upper and lower completions (e.g., since the single trip well completion system 22 is instead an integrated unit). Although illustrated as being used with the embodiment of the single trip well completion system 22 illustrated in FIGS. 4 and 5, the sensor cables and/or fiber optic lines 58 and associated reservoir monitoring and/or flow control tools 60 may be used with the other embodiments of the single trip well completion system 22 described herein (e.g., the embodiments illustrated in FIGS. 2 and 3, which utilize a tubing blanking device 46).

[0052] In addition, in certain embodiments, the single trip well completion system 22 may include one or more flow control valves (not shown) along with one or more open hole packers (not shown), which may facilitate zonal isolation and control production flow rates from each zone in the sandface completion. In certain embodiments, the bypass ports 62 of the production packer 38 also allow control lines (e.g., hydraulic lines, electric lines, and so forth) for the SCSSV 42, the surface-controlled barrier valve 54, the one or more flow control vales (not shown), as well as for any of the components of the single trip well completion system 22 that may be controlled by a control system 64 located at the surface 26 of the well 10.

[0053] Returning now to FIG. 1, in certain embodiments, the control system 64 may include a processor 66 and memory 68 that may be configured to store instructions that the processor 66 executes to control any or all of the components of the single trip well completion system 22 described herein to complete the well 10. For example, in certain embodiments, the control system 64 may control the various components of the single trip well completion system 22 based at least in part on data received from the reservoir monitoring and/or flow control tools 60 via the sensor cables and/or fiber optic lines 58.

[0054] FIG. 7 is a block diagram of a method 70 of installing the single trip well completion system 22 in a wellbore 12 of an open hole well 10 as an integrated unit in a single trip, in accordance with embodiments of the present disclosure. As illustrated, in certain embodiments, the method 70 includes running the single trip well completion system 22 downhole into the well 10 as an integrated unit (block 72). In addition, in certain embodiments, the method 70 includes blocking fluid flow radially outward through the standalone screen 32 of the single trip well completion system 22 from the interior passageway 36 of the single trip well completion system 22 into the annulus 34 formed between the single trip well completion system 22 and the wellbore 12 of the well 10 (while allowing fluid flow radially inward, in the opposite direction) while the single trip well completion system 22 is run downhole into the well 10 (block 74). In addition, in certain embodiments, the method 70 includes allowing bi-directional radial flow through the stand-alone screen 32 of the single trip well completion system 22 after the single trip well completion system 22 has been run downhole into the well 10 (block 76).

[0055] The embodiments of the single trip well completion system 22 described herein provide myriad benefits over conventional two-trip well completion systems. For example, the embodiments described herein provide cost savings through a single trip completion installation, which also significantly reduces rig time over conventional two-trip completion installations. In particular, time is saved because there is no requirement to run and retrieve, for example, washpipe and drillpipe strings to convey the stand-alone screens to depth. Furthermore, the embodiments described herein do not require that a fluid loss control device, sealbore extension, and sealbore packer be run into the wellbore 12. The embodiments described herein also reduce the amount of rental equipment (e.g., a sealbore packer setting tool, sealbore packer retrieving tool, internal washpipe, and other handling equipment) required for completion of the well 10.

[0056] Furthermore, the embodiments described herein also eliminate the risk of failure of a fluid loss control device prior to deployment of a separate upper completion, and the associated adverse effects that may be caused to the reservoir 14 due to fluid loss, and so forth. In addition, in embodiments that utilize the surface-controlled barrier valve 54, there is no need to have intervention to set the production packer 38. Rather, the production packer 38 may instead be set by pressuring up the tubular string 24 of the single trip well completion system 22 against the surface-controlled barrier valve 54, which will act as a tubing blanking device 46. In other embodiments, the production packer 38 may be set via control lines.

[0057] In addition, the embodiments described herein facilitate the application of filter cake breaker fluid across the open hole in order to dissolve the filter cake and simplify the flowback process, thereby enhancing the production from and/or injection into the reservoir 14 by making sure that all sections of the reservoir 14 are communicating with the wellbore 12. Furthermore, the embodiments described herein enable effective removal of the filter cake while preventing erosion during the life cycle of the well 10, as well as preventing damage to, for example, surface separators due to solids from the filter cake flowing back to the surface 26 of the well 10 during production.

[0058] In addition, the embodiments described herein eliminate the need to have disconnect tools (e.g., wetmate disconnect tools) in order to deploy the reservoir monitoring and/or flow control tools 60 across the sandface, thereby significantly reducing the risk and complexity of operation of the single trip well completion system 22 as compared to conventional two-step completion systems. Rather, as described in greater detail with reference to FIG. 6, the bypass ports 62 of the production packer 38 facilitate the sensor cables and/or fiber optic lines 58 to be connected to both the reservoir monitoring and/or flow control tools 60 as well as the control system 64 located at the surface 26 of the well 10, which may use data from the reservoir monitoring and/or flow control tools 60 to control the various components of the single trip well completion system 22. With this greater well knowledge, the intelligent completion design (e.g., with zonal isolation and control) enables the control system 64 to act on this data and optimize production. The data gathered presents more information to further understand and analyze performance of the reservoir 14.

[0059] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.

Claims

1. A method, comprising:

running an integrated well completion string downhole into a well as an integrated unit, wherein the integrated well completion string comprises a surface-controlled subsurface safety valve (SCSSV), a production packer disposed downhole with respect to the SCSSV, a standalone screen disposed downhole with respect to the production packer, and a washdown shoe disposed downhole with respect to the stand-alone screen;

blocking fluid flow radially outward through the stand-alone screen from an interior passageway of the integrated well completion string into an annulus formed between the integrated well completion string and a wellbore of the well while the integrated well completion string is run downhole into the well; and

allowing bi-directional radial fluid flow through the stand-alone screen after the integrated well completion string has been run downhole into the well.

2. The method of claim 1, comprising allowing fluid flow radially inward through the stand-alone screen from the annulus into the interior passageway of the integrated well completion string while the integrated well completion string is run downhole into the well.

3. The method of claim 1, wherein allowing bi-directional radial flow through the stand-alone screen after the integrated well completion string has been run downhole into the well comprises allowing fluid flow radially outward through the stand-alone screen from the interior passageway of the integrated well completion string into the annulus, and allowing fluid flow radially inward through the stand-alone screen from the annulus into the interior passageway of the integrated well completion string.

4. The method of claim 1, comprising using the SCSSV to block uncontrolled fluid flow uphole through the interior passageway of the integrated well completion string.

5. The method of claim 1, comprising using the production packer to anchor the integrated well completion string within the wellbore of the well.

6. The method of claim 1, comprising using the washdown shoe to allow fluid flow from the interior passageway of the integrated well completion string into the annulus, and to block fluid flow from the annulus into the interior passageway of the integrated well completion string.

7. The method of claim 1, comprising running the integrated well completion string downhole into the well as an integrated unit in a single run.

8. A well completion system, comprising:

an integrated well completion string configured to be run downhole into a well as an integrated unit to complete the well, wherein the integrated well completion string comprises:

a surface-controlled subsurface safety valve (SCSSV) configured to block uncontrolled fluid flow uphole through an interior passageway of the integrated well completion string;

a production packer configured to anchor the integrated well completion string within a wellbore of the well;

a stand-alone screen configured to block fluid flow radially outward from the interior passageway of the integrated well completion string into an annulus formed between the integrated well completion string and the wellbore of the well while the integrated well completion string is run downhole into the well, and to allow bi directional radial fluid flow after the integrated well completion string has been run downhole into the well; and

a washdown shoe configured to allow fluid flow from the interior passageway of the integrated well completion string into the annulus, and to block fluid flow from the annulus into the interior passageway of the integrated well completion string.

9. The well completion system of claim 8, wherein the integrated well completion string comprises a tubing blanking device disposed between the production packer and the stand-alone screen along a central axis of the wellbore of the well.

10. The well completion system of claim 9, wherein the integrated well completion string comprises a circulation sleeve disposed between the production packer and the tubing blanking device along a central axis of the wellbore of the well.

11. The well completion system of claim 8, wherein the integrated well completion string comprises a barrier valve disposed between the production packer and the stand-alone screen along a central axis of the wellbore of the well.

12. The well completion system of claim 11, wherein the integrated well completion string comprises a pressure-activated disconnect joint disposed between the barrier valve and the stand-alone screen along a central axis of the wellbore of the well.

13. The well completion system of claim 8, wherein the integrated well completion string comprises gas lift mandrels disposed between the SCSSV and the production packer along a central axis of the wellbore of the well.

14. The well completion system of claim 8, wherein the integrated well completion string comprises a permanent downhole gauge disposed between the SCSSV and the production packer along a central axis of the wellbore of the well.

15. A method, comprising :

running an integrated well completion string downhole into a well as an integrated unit, wherein the integrated well completion string comprises a surface-controlled subsurface safety valve (SCSSV), a production packer disposed downhole with respect to the SCSSV, a standalone screen disposed downhole with respect to the production packer, and a washdown shoe disposed downhole with respect to the stand-alone screen.

16. The method of claim 15, comprising blocking fluid flow radially outward through the stand-alone screen from an interior passageway of the integrated well completion string into an annulus formed between the integrated well completion string and a wellbore of the well while the integrated well completion string is run downhole into the well.

17. The method of claim 16, comprising allowing fluid flow radially inward through the stand-alone screen from the annulus into the interior passageway of the integrated well completion string while the integrated well completion string is run downhole into the well.

18. The method of claim 16, comprising allowing bi-directional radial fluid flow through the stand-alone screen after the integrated well completion string has been run downhole into the well.

19. The method of claim 18, wherein allowing bi-directional radial flow through the stand-alone screen after the integrated well completion string has been run downhole into the well comprises allowing fluid flow radially outward through the stand-alone screen from the interior passageway of the integrated well completion string into the annulus, and allowing fluid flow radially inward through the stand-alone screen from the annulus into the interior passageway of the integrated well completion string.

20. The method of claim 15, comprising running the integrated well completion string downhole into the well as an integrated unit in a single run.