Method and apparatus for gravel packing with a pressure maintenance tool

• US 6,575,246 B2
• Filed: 08/14/2001
• Issued: 06/10/2003
• Est. Priority Date: 04/30/1999
• Status: Expired due to Fees

• Current Assignee: Schlumberger Technology Corporation (SLB)
• Original Assignee: Schlumberger Technology Corporation (SLB)
• Inventors: Schutz, Micah L., Anyan, Steven L., Bixenman, Patrick W., Pramann, James A. II
• Primary Examiner(s): SCHOEPPEL, ROGER J
• Application Number:
  US09/929,867
• Publication Number:
  US 20020036087A1
• Time in Patent Office: 665 Days
• Field of Search: 166/51, 166/191, 166/194, 166/276, 166/278, 166/374, 166/377, 166/386, 166/387
• US Class Current: 166/278
• CPC Class Codes: E21B 2200/04 Ball valves
• CPC Class Codes: E21B 34/12 operated by movement of casings or tubings
• CPC Class Codes: E21B 43/04 Gravelling of wells
• CPC Class Codes: E21B 43/045 Crossover tools

Abstract

A method and apparatus for performing a gravel pack operation includes a bypass mechanism (e.g., a bypass valve) that is actuatable between plural positions. The bypass mechanism is part of a tool assembly, with the bypass mechanism providing different flow paths through the tool assembly corresponding to the plural positions of the bypass mechanism. For example, if the bypass mechanism is in a first position, an elevated pressure is communicated from an annular region outside a tool string to a target wellbore section. On the other hand, if the bypass mechanism is in the second position, the elevated pressure is communicated from inside the tool string to the target wellbore section. In either position, an overbalance condition is maintained in the target wellbore section so that swabbing effects are reduced or eliminated due to movement of the tool assembly during a gravel pack operation.

Claims

1. A method for use in a wellbore, comprising:

performing a gravel pack operation with a tool assembly in a section of the wellbore, the tool assembly attached to a tool string;

providing a bypass mechanism in the tool assembly;

actuating the bypass mechanism between at least a first position and a second position using a remote signal;

maintaining communication of an elevated pressure through the bypass mechanism to the wellbore section to provide an overbalance condition in the wellbore section,

the bypass mechanism communicating pressure from inside the tool string to the wellbore section if the bypass mechanism is in the first position, and

the bypass mechanism communicating pressure from an annular region outside the tool string to the wellbore section if the bypass mechanism is in the second position; and

initially setting the bypass mechanism to the second position prior to performing the gravel pack operation.

2. The method of claim 1, wherein performing the gravel pack operation with the tool assembly comprises actuating a sealing element against the wellbore, and wherein maintaining communication of the elevated pressure comprises communicating the elevated pressure past the sealing element with the bypass mechanism.

3. The method of claim 1, wherein actuating the bypass mechanism using the remote signal comprises actuating the bypass mechanism using applied pressure.

4. The method of claim 1, wherein providing the bypass mechanism comprises providing a bypass valve having plural positions.

5. The method of claim 1, further comprising providing a bore through the tool assembly, and providing a valve to control flow through the bore.

6. The method of claim 5, wherein providing the valve comprises providing a ball valve.

7. The method of claim 5, further comprising actuating the valve to a first position to allow flow through the bore and to a second position to block flow through the bore.

8. The method of claim 7, further comprising locking the valve in the first position and applying a predetermined force to the tool assembly to unlock the valve.

9. The method of claim 8, wherein applying the predetermined force comprises applying a set-down force.

10. The method of claim 8, wherein locking the valve is performed during at least run-in and packer test operations.

11. The method of claim 10, wherein unlocking the valve is performed to enable the valve to be closed during a reverse circulate operation.

12. The method of claim 1, further comprising:

setting the bypass mechanism to the first position; and

after setting the bypass mechanism to the first position, pressure testing the packer in the tool assembly by applying an elevated pressure to the annular region.

13. The method of claim 12, wherein setting the bypass mechanism to the first position is performed after initially setting the bypass mechanism to the second position, the method further comprising:

after setting the bypass mechanism to the first position, setting the bypass mechanism back to the second position; and

performing the gravel pack operation with the bypass mechanism in the second position.

14. A method for use in a wellbore, comprising:

performing a gravel pack operation with a tool assembly in a section of the wellbore;

actuating a bypass mechanism in the tool assembly between plural positions during phases of the gravel pack operation;

maintaining communication of an elevated pressure through the bypass mechanism to the wellbore section to provide an overbalance condition in the wellbore section, the elevated pressure communicated through different paths in the tool assembly corresponding to the plural positions of the bypass mechanism,

wherein actuating the bypass mechanism comprises actuating the bypass mechanism using applied fluid pressure; and

providing a flow control device to control flow through an inner bore of the tool assembly.

15. The method of claim 14, wherein performing the gravel pack operation comprises actuating a sealing element against an inner surface of the wellbore, wherein maintaining communication of the elevated pressure comprises maintaining communication of the elevated pressure past the actuated sealing element.

16. The method of claim 15, further comprising providing at least a portion of the bypass mechanism inside a device on which the sealing element is mounted.

17. The method of claim 15 further comprising providing a service tool having the bypass mechanism through a device on which the sealing element is mounted.

18. The method of claim 14 further comprising maintaining the flow control device in an open position to enable fluid flow through the inner bore of the service tool until after a circulate phase of the gravel pack operation is completed.

19. The method of claim 18, further comprising locking the flow control device in the open position.

20. The method of claim 19, further comprising lifting and setting down the service tool to unlock the flow control device.

21. The method of claim 14, further comprising providing a return flow path through the tool assembly, wherein providing the bypass mechanism comprises providing the bypass mechanism having a valve to control fluid flow through the return path.

22. The method of claim 21, further comprising maintaining the valve closed during run-in of the tool assembly to direct washdown fluid to the lower end of a service string comprising the tool assembly and to prevent flow of the washdown fluid up the return path.

23. The method of claim 21, further comprising actuating the valve open to enable communication of the elevated pressure to the wellbore section.

24. The method of claim 14, wherein maintaining communication of the elevated pressure comprises:

maintaining communication of the elevated pressure from an annular region outside a tool string if the bypass mechanism is in a first position,

maintaining communication of the elevated pressure from inside the tool string if the bypass mechanism is in a second position.

25. The method of claim 14, wherein actuating the bypass mechanism comprises actuating a bypass valve having at least a first position and a second position.

26. The method of claim 25, wherein performing the gravel pack operation comprises setting a packer in the tool assembly, testing the packer, performing a circulate operation, and performing a reverse operation, wherein actuating the bypass valve comprises actuating the bypass valve to the second position for testing the packer and actuating the bypass valve to the first position for setting the packer, performing the circulate operation, and performing the reverse operation.

27. The method of claim 26, wherein the tool assembly comprises a service tool having the bypass valve, and wherein performing the circulate operation comprises:

lifting the service tool and subsequently setting the service tool down; and

pumping gravel slurry through the service tool and out of a port of the tool assembly.

28. The method of claim 14, wherein providing the flow control device comprises providing a ball valve.

29. A gravel pack apparatus attachable to a tool string, comprising:

a tool assembly comprising a sealing element and a bypass mechanism,

the bypass mechanism adapted to communicate an elevated pressure past the sealing element to a target wellbore section to maintain an overbalance condition in the target wellbore section,

the bypass mechanism having an actuator that is adapted to be remotely actuatable by a remote signal between at least a first position and a second position,

the bypass mechanism if in the first position adapted to communicate pressure from outside the tool string to the target wellbore section, and the bypass mechanism if in the second position adapted to isolate a region outside the tool string above the sealing element and to communicate pressure from inside the tool string to the target wellbore section.

30. The apparatus of claim 29, wherein the sealing element comprises a packer.

31. The apparatus of claim 29, wherein the bypass mechanism comprises a bypass valve.

32. The apparatus of claim 29, further comprising a flow control element positioned in a bore of the tool assembly to control flow through the bore, the flow control element maintained in an open position to enable maintenance of the elevated pressure through the tool assembly bore to the target wellbore section.

33. The apparatus of claim 29, wherein the flow control element comprises a ball valve.

34. The apparatus of claim 29, wherein the bypass mechanism has plural positions.

35. The apparatus of claim 34, wherein the tool assembly has plural flow paths that are opened in response to corresponding positions of the bypass mechanism.

36. The apparatus of claim 29, wherein the bypass mechanism comprises a pressure-activated mechanism responsive to an applied pressure.

37. A gravel pack apparatus for use in a wellbore, comprising:

a sealing element adapted to seal against the wellbore; and

a tool assembly comprising a bypass mechanism having at least first and second positions, the bypass mechanism adapted to communicate elevated pressure to a wellbore section past the sealing element to provide an overbalance condition in the wellbore section, the bypass mechanism in the first position to communicate elevated pressure from an annular region outside the tool assembly to the wellbore section, the bypass mechanism in the second position to communicate elevated pressure from inside the tool assembly to the wellbore section,

the bypass mechanism having a remotely-operable actuator that is adapted to be operated without user manipulation of the tool assembly to move the bypass mechanism between the at least first and second positions.

38. The gravel pack apparatus of claim 37, wherein the tool assembly has a first flow path and a second flow path, the bypass mechanism adapted to enable fluid communication in the first flow path if the bypass mechanism is in the first position, and the bypass mechanism adapted to enable fluid communication in the second flow path if the bypass mechanism is in the second position.

39. The gravel pack apparatus of claim 37, wherein the tool assembly comprises an inner bore and a flow control element adapted to control flow through the inner bore, the flow control element in an open position cooperable with the bypass mechanism to communicate the elevated pressure to the wellbore section.

40. The gravel pack apparatus of claim 39, wherein the flow control element comprises a ball valve.

41. The gravel pack apparatus of claim 39, wherein the flow control element is adapted to be locked open by a shear element.

42. The gravel pack apparatus of claim 41, wherein the service tool is adapted to be lifted and set down to break the shear element.

43. The gravel pack apparatus of claim 37, wherein the bypass mechanism comprises a bypass valve.