Downhole completion assembly and related systems and methods of use

Abstract

A completion assembly suitable for use in a wellbore, the completion assembly having a first sub engaged with a second sub in an assembled or run-in configuration. In the assembled or run-in configuration, the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both.

What is claimed is: 
     
         1 . A completion assembly for use in a wellbore, the completion assembly comprising:
 a first sub configured to engage with a workstring; and   a second sub coupled with the first sub in a run-in configuration, the second sub comprising a second sub component;   
       wherein in the run-in configuration the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both, 
       wherein during a setting sequence at least a portion of the first sub is in fluid communication with the primary pressure chamber, and also during the setting sequence the second sub component is configured with a working surface in fluid communication with the first sub, and 
       wherein the first sub is configured to convey a non-mechanical force to the working surface to move the completion assembly from the run-in configuration to a disconnected configuration. 
     
     
         2 . The completion assembly of  claim 1 , wherein the primary pressure chamber is in in direct proximity to the working surface. 
     
     
         3 . The completion assembly of  claim 1 , wherein the non-mechanical force comprises a fluid pressure acting against the working surface, and wherein acting against the working surface results in a change of a volume dimension associated with the primary pressure chamber. 
     
     
         4 . The completion assembly of  claim 1 , wherein in the disconnected configuration the working surface remains in the wellbore for a period of time after the first sub is retrieved out of the wellbore, and wherein the completion assembly further comprises an isolation device disposed at least partially within or in direct proximity to the primary pressure chamber in the run-in configuration. 
     
     
         5 . The completion assembly of  claim 1 , wherein in the run-in configuration the primary pressure chamber is fluidly isolated from any external wellbore fluid. 
     
     
         6 . The completion assembly of  claim 1 , wherein in the disconnected configuration the first sub is disengaged from the second sub, and the first sub is retrievable out of the wellbore, and
 wherein in the disconnected configuration an at least a portion of the second sub remains in the wellbore in support of an at least one downhole operation that occurs after the first sub is retrieved out of the wellbore.   
     
     
         7 . The completion assembly of  claim 6 , wherein the at least one downhole operation comprises hydraulic fracturing. 
     
     
         8 . The completion assembly of  claim 1 , wherein in the run-in configuration the completion assembly comprises a second pressure chamber maintained at a respective pressure that is also isolated from the external wellbore pressure as the completion assembly is run into the wellbore. 
     
     
         9 . The completion assembly of  claim 1 , wherein in each of the run-in configuration, the disconnected configuration, and during the setting sequence, the first sub lacks any moving parts coupled thereto other than of the second sub. 
     
     
         10 . The completion assembly of  claim 1 , wherein the first sub comprises a power charge ignitable to create or increase an inner fluid pressure that is conveyed from the first sub to the working surface. 
     
     
         11 . The completion assembly of  claim 1 , wherein in the run-in configuration the completion assembly is void of each of: a setting tool adapter or adapter kit, a barrel piston, and a setting sleeve. 
     
     
         12 . A completion assembly for use with a workstring positioned in a wellbore, the completion assembly comprising:
 a first sub coupled with the workstring;   a second sub coupled with the first sub in a run-in configuration, the second sub comprising a second sub component;   
       wherein in the run-in configuration the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both, 
       wherein during a setting sequence at least a portion of the first sub is in fluid communication with the primary pressure chamber, and also during the setting sequence the second sub component is configured with a working surface in fluid communication with the first sub, and 
       wherein the completion assembly is void of each of: a setting tool adapter or adapter kit, a barrel piston, and a setting sleeve. 
     
     
         13 . The completion assembly of  claim 12 , wherein the first sub is configured to convey a sufficient amount of a non-mechanical force to the working surface to move the completion assembly from the run-in configuration to a disconnected configuration, and wherein the completion assembly further comprises an isolation device and an isolation device seat disposed at least partially within or in direct proximity to the primary pressure chamber in the run-in configuration. 
     
     
         14 . The completion assembly of  claim 13 , wherein the primary pressure chamber is in in direct proximity to the working surface. 
     
     
         15 . The completion assembly of  claim 13 , wherein the non-mechanical force comprises a fluid pressure acting against the working surface, and wherein acting against the working surface results in a change of a volume dimension associated with the primary pressure chamber. 
     
     
         16 . The completion assembly of  claim 12 , wherein in the disconnected configuration the working surface remains in the wellbore for a period of time after the first sub is retrieved out of the wellbore, and wherein the completion assembly further comprises an isolation device disposed at least partially within or in direct proximity to the primary pressure chamber in the run-in configuration. 
     
     
         17 . The completion assembly of  claim 12 , wherein the first sub comprises a power charge mandrel, wherein the power charge mandrel is in fluid communication with the primary pressure chamber in the run-in configuration, and wherein the second sub comprises a frac plug configured with a component surface sealingly engaged with the power charge mandrel in the run-in configuration. 
     
     
         18 . The completion assembly of  claim 17 , wherein the first sub and the second sub are pre-assembled engaged together at a location measured by a straight-line distance range of at least 0.5 miles to no more than 10,000 miles away from a wellhead associated with the wellbore. 
     
     
         19 . The completion assembly of  claim 18 , wherein the second sub comprises an at least one component made of a reactive material. 
     
     
         20 . A downhole setting system for use in a wellbore, the system comprising:
 a completion assembly comprising:
 a first sub; 
 a second sub comprising a component having a working surface, the second sub engaged with the first sub in a run-in configuration, 
   
       wherein in the run-in configuration the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both, 
       wherein during a setting sequence at least a portion of the first sub is in fluid communication with the primary pressure chamber, and also during the setting sequence the second sub component is configured with the working surface in fluid communication with the first sub, 
       wherein in a disconnected configuration the first sub is disengaged from the second sub, and the first sub is retrievable out of the wellbore, and 
       wherein in the disconnected configuration the working surface is not retrieved out of the wellbore. 
     
     
         21 . The completion assembly of  claim 20 , wherein the first sub is configured to convey a sufficient amount of a non-mechanical force to the working surface to move the completion assembly from the run-in configuration to the disconnected configuration, and wherein the completion assembly further comprises an isolation device and an isolation device seat disposed at least partially within or in direct proximity to the primary pressure chamber in the run-in configuration. 
     
     
         22 . The completion assembly of  claim 21 , wherein the completion assembly is void of each of: a setting tool adapter or adapter kit, a barrel piston, and a setting sleeve. 
     
     
         23 . The downhole setting system of  claim 20 , wherein in the primary pressure chamber maintained at a first pressure that is isolated from an external wellbore pressure as the completion assembly is run into the wellbore in the run-in configuration. 
     
     
         24 . The downhole setting system of  claim 23 , wherein in the run-in configuration the first sub comprises: a power charge mandrel configured with a power charge disposed therein, and wherein in the run-in configuration the second sub comprises a downhole tool having at least one surface sealingly engaged with the power charge mandrel. 
     
     
         25 . A downhole setting system for use in a wellbore, the system comprising:
 a completion assembly comprising:
 a first sub engaged with a workstring; 
 a second sub engaged with the first sub in a run-in configuration, 
   
       wherein in the run-in configuration the completion assembly is configured to maintain pressure integrity of a primary pressure chamber disposed at least partially within at least one of: the first sub, the second sub, or both, 
       wherein during a setting sequence at least a portion of the first sub is in fluid communication with the primary pressure chamber, and also during the setting sequence the second sub component is configured with a working surface in fluid communication with the first sub, 
       wherein the first sub is configured to convey a non-mechanical force to the working surface during the setting sequence to move the completion assembly from the run-in configuration to a disconnected configuration, and 
       wherein the completion assembly further comprises an isolation device and an isolation device seat disposed at least partially within or in direct proximity to the primary pressure chamber in the run-in configuration. 
     
     
         26 . The downhole setting system of  claim 25 , wherein in the run-in configuration the completion assembly is void of at least one of: a setting tool adapter or adapter kit, a barrel piston, a setting sleeve, and combinations thereof. 
     
     
         27 . The downhole setting system of  claim 26 , wherein the first sub is void of any moving parts or components used in moving the second sub from the run-in configuration to a set configuration. 
     
     
         28 . The downhole setting system of  claim 27 , wherein the first sub and the second sub are pre-assembled for engagement together for use in the run-in configuration at a location at least 0.5 miles away from a wellhead associated with the wellbore. 
     
     
         29 . The downhole setting system of  claim 27 , wherein in the run-in configuration the first sub comprises: a power charge mandrel configured with a power charge disposed therein, and wherein in the run-in configuration the second sub comprises a downhole tool having at least one component sealingly engaged with the power charge mandrel. 
     
     
         30 . The downhole setting system of  claim 27 , wherein in a disconnected configuration the first sub is disengaged from the second sub, and the first sub is retrievable out of the wellbore, and wherein in the disconnected configuration at least a portion of the second sub remains engaged with a tubular disposed in the wellbore for at least a period of time after the first sub is retrieved out of the wellbore.