Single Trip Multi-Zone Completion Systems and Methods

Abstract

Disclosed are systems and methods of producing from multiple production zones with a single trip multi-zone completion system. One single trip multi-zone completion system includes an outer completion string having at least one sand screen arranged thereabout and an interval control valve coupled to the at least one sand screen, a production tubing communicably coupled to the outer completion string at a crossover coupling, a control line extending external to the production tubing and being communicably coupled to the crossover coupling, and a surveillance line extending from the crossover coupling external to the outer completion string and interposing the at least one formation zone and the at least one sand screen, the surveillance line being communicably coupled to the interval control valve.

1 . A single trip multi-zone completion system, comprising:
 an outer completion string having at least one sand screen arranged thereabout and an interval control valve coupled to the at least one sand screen;   a production tubing communicably coupled to the outer completion string at a crossover coupling;   a control line extending external to the production tubing and being communicably coupled to the crossover coupling; and   a surveillance line extending from the crossover coupling external to the outer completion string and interposing the at least one formation zone and the at least one sand screen, the surveillance line being communicably coupled to the interval control valve.   
     
     
         2 . The system of  claim 1 , further comprising a fluid loss valve arranged within the outer completion string. 
     
     
         3 . The system of  claim 1 , wherein the crossover coupling is at least one of an electro-hydraulic wet connect providing an electrical wet mate connection and an inductive coupler providing an electromagnetic connection. 
     
     
         4 . (canceled) 
     
     
         5 . The system of  claim 1 , wherein the control line comprises one or more hydraulic lines, one or more electrical lines, and/or one or more fiber optic lines. 
     
     
         6 . The system of  claim 1 , wherein the surveillance line comprises one or more hydraulic lines, one or more electrical lines, and/or one or more fiber optic lines. 
     
     
         7 . The system of  claim 1 , wherein the surveillance line includes one or more associated gauges and/or sensors configured to measure and report fluid and well parameters external to the outer completion string. 
     
     
         8 . The system of  claim 7 , wherein the fluid and well environment parameters comprise at least one of pressure, temperature, fluid density, seismic activity, vibration, compaction, and any combination thereof. 
     
     
         9 . (canceled) 
     
     
         10 . The system of  claim 1 , further comprising a flow control device arranged within the at least one interval control valve and movable between an open position and a closed position. 
     
     
         11 . The system of  claim 10 , wherein the flow control device is a sleeve, and when in the open position one or more flow ports defined in the outer completion string are exposed and allow fluid flow into the interior of the production tubing. 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . A method of producing from one or more formation zones, comprising:
 arranging an outer completion string within a wellbore adjacent the one or more formation zones, the outer completion string having at least one sand screen arranged thereabout and an interval control valve coupled to the at least one sand screen;   communicably coupling a production tubing to the completion string at a crossover coupling having one or more control lines extending thereto;   communicably coupling a surveillance line to the one or more control lines at the crossover coupling, the surveillance line extending from the crossover coupling external to the outer completion string and interposing the one or more formation zones and the at least one sand screen; and   actuating the at least one interval control valve to initiate production into the outer completion string, the at least one interval control valve being communicably coupled to the surveillance line.   
     
     
         15 . (canceled) 
     
     
         16 . The method of  claim 14 , further comprising measuring one or more fluid and well environmental parameters external to the outer completion string with one or more gauges and/or sensors associated with the surveillance line. 
     
     
         17 . (canceled) 
     
     
         18 . The method of  claim 14 , wherein actuating the at least one interval control valve further comprises regulating a fluid flow through the sand screen and into the outer completion string with the at least one interval control valve. 
     
     
         19 . The method of  claim 18 , further comprising choking the fluid flow into the outer completion string with the at least one interval control valve. 
     
     
         20 . The method of  claim 14 , wherein actuating the at least one interval control valve further comprises moving a flow control device arranged within the at least one sand screen between a closed position and an open position. 
     
     
         21 . The method of  claim 20 , further comprising choking a fluid flow into the outer completion string by incrementally moving the flow control device partially between the closed and open positions with the at least one interval control valve. 
     
     
         22 . A method of deploying a single trip multi-zone completion system, comprising:
 locating an inner service tool within an outer completion string arranged within a wellbore that penetrates one or more formation zones, the outer completion string having at least one sand screen arranged thereabout and an interval control valve coupled to the at least one sand screen;   treating the one or more formation zones with the inner service tool, wherein a surveillance line extends external to the outer completion string and interposes the one or more formation zones and the at least one sand screen;   retrieving the inner service tool from within the outer completion string;   communicably coupling a production tubing to the completion string at a crossover coupling having one or more control lines extending thereto;   communicably coupling the surveillance line to the one or more control lines at the crossover coupling; and   actuating the at least one interval control valve to initiate production into the outer completion string, the at least one interval control valve being communicably coupled to the surveillance line.   
     
     
         23 . The method of  claim 22 , wherein retrieving the inner service tool further comprises closing a fluid loss valve arranged within the outer completion string. 
     
     
         24 . The method of  claim 23 , further comprising opening the fluid loss valve once the production tubing is communicably coupled to the completion string. 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . The method of  claim 22 , further comprising measuring one or more fluid and well environmental parameters external to the outer completion string with one or more gauges and/or sensors associated with the surveillance line. 
     
     
         28 . The method of  claim 27 , further comprising measuring compaction of a gravel pack in the one or more formation zones with one or more gauges and/or sensors. 
     
     
         29 . The method of  claim 27 , further comprising monitoring the one or more formation zones for water break through or zonal depletion with the one or more gauges and/or sensors. 
     
     
         30 . The method of  claim 22 , wherein actuating the at least one interval control valve further comprises regulating a fluid flow through the sand screen and into the outer completion string with the at least one interval control valve. 
     
     
         31 . The method of  claim 30 , further comprising choking the fluid flow into the outer completion string with the at least one interval control valve. 
     
     
         32 . The method of  claim 22 , wherein actuating the at least one interval control valve further comprises moving a flow control device arranged within the at least one sand screen between a closed position and an open position. 
     
     
         33 . The method of  claim 32 , further comprising choking a fluid flow into the outer completion string by incrementally moving the flow control device partially between the closed and open positions with the at least one interval control valve. 
     
     
         34 . The method of  claim 22 , wherein treating the one or more formation zones comprises hydraulically fracturing and gravel packing the one or more formation zones. 
     
     
         35 . The method of  claim 22 , further comprising:
 detaching the production tubing from the outer completion string;   retrieving the production tubing to a well surface while the outer completion string remains within the wellbore adjacent the one or more formation zones;   re-locating the production tubing within the outer completion string; and   communicably coupling the production tubing to the outer completion string at the crossover coupling once again.