Intelligent Well Control System for Three or More Zones

Abstract

An intelligent well system can service three or more zones that have gravel packed screens. A modular system features a screen and a surface controlled production valve on an internal blank pipe that internally straddles the screen. A gravel exit valve is disposed above the blank pipe and the blank pipe can optionally have a fluid loss control valve. A gravel pack/fracturing assembly can engage each module and close the fluid loss valve and gravel outlet valve on the way out of a module. Optionally the fluid loss valve can be eliminated if the gravel packing and fracturing string has the ability to power the production valve. The modules can be connected by wet connects as can the production string to make the intelligent well system functional from the surface.

1 . An intelligent well completion system for downhole use, comprising:
 a tubular string with at least two screens and at least one packer to separate the screens into different zones and a gravel port for each zone;   at least a first and a second axially spaced apart valve assemblies respectively associated with said screens, said valve assemblies operable from the surface of the well to selectively allow flow through said screens without intervention in said string.   
   
   
       2 . The system of  claim 1 , wherein:
 a plurality of internal pipes each spanning a respective screen internally of said string and further supporting one of said valve assemblies.   
   
   
       3 . The system of  claim 2 , wherein:
 said valve assemblies are actuated from the surface through a control system extending outside said string.   
   
   
       4 . The system of  claim 3 , wherein:
 said control system further comprises at least one discrete line to each valve assembly further comprising at least one quick connection.   
   
   
       5 . The system of  claim 4 , wherein:
 at least one said line is a hydraulic line that extends through said packer.   
   
   
       6 . The system of  claim 2 , wherein:
 said string comprises a gravel port valve and a fluid loss valve associated with each said screen with said fluid loss valve mounted to the internal pipe associated with a respective screen.   
   
   
       7 . The system of  claim 6 , further comprising:
 a frac pack assembly further comprising a crossover and a sleeve shifter to selectively operate said gravel port valve and said fluid loss valve to selectively deliver gravel or fluid through said gravel port and to thereafter close off an associated screen with said fluid loss valve.   
   
   
       8 . The system of  claim 3 , further comprising:
 at least one sensor adjacent said screen connected to the surface through said control system for transmission of data between said screen and said surface in real time.   
   
   
       9 . The system of  claim 8 , further comprising:
 said sensor comprises a fiber optic cable mounted to said screen to detect strain on said screen.   
   
   
       10 . The system of  claim 3 , further comprising:
 said string comprises a gravel port valve associated with each said screen;   a frac pack assembly further comprising a crossover and a sleeve shifter to selectively operate said gravel port valve;   said valve assemblies are actuated from the surface through a first control system associated with said frac pack assembly.   
   
   
       11 . The system of  claim 3 , further comprising:
 said valve assemblies are additionally controlled through a second control system that runs outside said string, thereby allowing a given valve assembly to be used as a fluid loss valve in conjunction with said frac pack assembly and as a production valve after removal of said frac pack assembly.   
   
   
       12 . The system of  claim 11 , further comprising:
 a sensor associated with at least one said screen to transmit to the surface through at least one said control system.   
   
   
       13 . The system of  claim 12 , further comprising:
 at least one said control system further comprises a fiber optic cable extending to said screen or a conduit extending to said screen for chemical injection.   
   
   
       14 . The system of  claim 3 , further comprising:
 at least three interconnected modules in said string, each featuring a gravel port, one of said screen spanned by an internal pipe, one of said valve assemblies on said internal pipe and a portion of said control system.   
   
   
       15 . The system of  claim 14 , wherein:
 at least two modules have end connections on said control system adapted for quick connection of said control system when said modules are assembled.   
   
   
       16 . The system of  claim 14 , wherein:
 at least one module has a control system component comprising at least one of a fiber optic cable, a sensor for well conditions, at least one hydraulic line or an open line for chemical injection.   
   
   
       17 . The system of  claim 14 , wherein:
 at least two modules have a seal bore at one end and seal at an opposite end for quick connection of adjacent modules.   
   
   
       18 . The system of  claim 17 , wherein:
 connecting seals on one module into a seal bore of an adjacent module also connects portions of said control system at the same time.   
   
   
       19 . The system of  claim 18 , wherein:
 the components of said control system that connect when modules are pushed together are aligned radially or axially.   
   
   
       20 . The system of  claim 14 , wherein:
 said valve assemblies further comprise hydraulically operated sliding sleeves that can be selectively positioned fully open or closed or at least one position in between.